Zavedení produktu Battery Management System do sériové výroby

Abstract

The Battery Management System (BMS) is quite modern equipment for monitoring of status of battery in car. Mechanical part of this product is currently produced by German company Schuilte+Co. GmbH. which has no capacity to cover increasing demand of customer (Audi, VW and Porsche). Therefore the Lear management decided to insource the production of BMS into Lear Corporation. Vyskov plant has been selected to build new assembly line and start with production of additional requested volume of BMS. The design of new assembly line was developed based on process flow and FMEA. Before all equipment for BMS assembly (brazing, laser welding, moulding and testing machines) was ordered the 3D model of designed assy line was created. The cardboard boxes were used for this purpose. 3D model was later used for simulation of production process to clarify the material flow and work of operators at line and to approve that the calculated cycle time is correct and attainable. Theoretical cycle time and capacity of each workplace was later balanced to ensure the smooth work and fluent operation of equipment based on one piece flow system. The next step of this project – transfer of lines for assy of electronics parts was evaluated from economical point of view. The savings resulting from this transfer were calculated and used as a base for Capex and investment approve at senior management of Lear Corporation. Currently the equipment for BMS assy is ordered and partially delivered and commissioned in Vyskov plant. During next weeks is planned the start-up procedure which contains mainly the Run at Rate study and capability study of both each workplace and assy line in general. Consequently the samples of assembled BMS will be sent to Valls plan in Spain to finish the BMS by assembly of electronics and then the testing according to customer request will follow to get customer’s approval.