BMW - Production Line Reprogramming 1/2
BMW had to reprogram an already existing production line, including its integration to the newest standards, to enable a new model release without stopping actual production. This modernization had to be implemented, documented, and delivered, including all needed trainings for the users, without stopping the actual production process. The project scope covered 7 main production lines in the general factory in Munich.
To address this problem, BMW's team worked hand-by-hand with external experts on the following solutions:
- Offline programming to minimize downtime
- Virtual commissioning of the programs to test functionality before implementation
- Complete start-up of the production line to ensure smooth operation
- Adjustment and development of HMI according to client requirements
- Process optimization for efficient production
- Collaboration with other project departments, such as electrical, mechanical, production planners, and design
- Working with customers, project managers, and electricians to solve functional problems on the existing lines
- Testing line functionalities to verify PLC program completeness
- Commissioning communication between PLCs and robots
- Working with simulation systems, such as WinMOD and RF Suite, to simulate the production line
- Providing training for the users to operate and maintain the production line
- Provision of functional documentation for the production line
- Production support to address any issues that may arise during production
The reprogramming of the production line was a success, with the team completing start-up and production support without stopping the actual production process. The virtual commissioning of the programs helped to test the functionality before implementation, minimizing downtime. The adjustment and development of the HMI provided an efficient interface for the users, while the process optimization resulted in efficient production. The collaboration with other project departments and the provision of training and functional documentation for the users ensured the continued success of the production line. The use of advanced technologies, such as gluing processes, laser welding, and automation with SIEMENS SIMATIC S7-300/400 and SIEMENS SIMATIC S7-1500 PLCs, helped to streamline production and improve efficiency.
In conclusion, BMW's successful reprogramming of the production line demonstrates the company's commitment to innovation and quality. The team's thorough approach to virtual commissioning, process optimization, and collaboration with other project departments resulted in a highly efficient production line. The training and functional documentation provided for the users ensured the continued success of the production line. The use of advanced technologies, such as gluing processes, laser welding, and automation with SIEMENS SIMATIC S7-300/400 and SIEMENS SIMATIC S7-1500 PLCs, helped to streamline production and improve efficiency, resulting in cost savings and increased productivity.
BMW utilized several advanced technologies for the production line reprogramming where production processes include gluing, part logistic management, brushing, framing, and optical quality tests. The team used SIEMENS SIMATIC S7-300/400 and SIEMENS SIMATIC S7-1500 PLCs for automation, and the TIA Portal V13 software was used for programming and configuration. Additional challenge was to combine together lines with different programming standard and nowadays equipment with different ages. The WinCC was used for HMI development, and the team also worked with ABB and Kuka robots. Additionally, the SIMATIC STEP7 V5.5 was used for programming and configuration, and ZenOn was used for HMI development.