{"id":29247,"date":"2018-11-12T18:17:33","date_gmt":"2018-11-12T23:17:33","guid":{"rendered":"https:\/\/digital.hbs.edu\/platform-rctom\/submission\/volkswagen-additive-manufacturing-as-a-tool-for-success\/"},"modified":"2018-11-12T18:17:33","modified_gmt":"2018-11-12T23:17:33","slug":"volkswagen-additive-manufacturing-as-a-tool-for-success","status":"publish","type":"hck-submission","link":"https:\/\/d3.harvard.edu\/platform-rctom\/submission\/volkswagen-additive-manufacturing-as-a-tool-for-success\/","title":{"rendered":"Volkswagen: Additive Manufacturing as a Tool for Success"},"content":{"rendered":"<p>In any production line, identifying and addressing bottlenecks is pivotal in order to optimize output, employee utilization, and reduce overall production costs.\u00a0 For large corporations like Volkswagen, which produced roughly 11 million passenger and commercial vehicles globally in 2017, every second of a cycle time counts [1].\u00a0 Given the maturity of their lines, operations have had to get creative in their means of optimization.\u00a0 Volkswagen Autoeuropa has identified one such solution in additive manufacturing.<\/p>\n<p><strong>Volkswagen Autoeuropa<\/strong><\/p>\n<p>Located in Palmela, Portugal, Volkswagen Autoeuropa was formed in 1991 as a joint venture between Ford Europe and Volkswagen Group.\u00a0 Since beginning operations in 1995, the assembly plant has produced parts for over 2.3 million vehicles [2].\u00a0 On average, the plant (which employs nearly 4,000 people) processes 100,000 orders per year, including vehicle upgrades and VW\u2019s Scirocco and Sharan range models [3].<\/p>\n<p><strong>Additive Manufacturing at VW Autoeuropa<\/strong><\/p>\n<p>Customized tooling, jigs, and fixtures are employed to effectively accomplish various tasks in the production line.\u00a0 These tools serve many purposes from properly aligning the liftgate badge to positioning the quarter window on the passenger doors. Traditionally, Volkswagen Autoeuropa relied on third-party manufacturers to design and supply them with manufacturing tools for every new run.\u00a0 The process typically followed the below format:<\/p>\n<ul>\n<li>Complete required paperwork to identify and contract third-party supplier.<\/li>\n<li>Work with supplier to develop initial design of tool.<\/li>\n<li>Receive and test prototype tool from supplier.<\/li>\n<li>Send part back to supplier with notes outlining required changes to optimize tool.<\/li>\n<li>Repeat trial-and-error approach.<\/li>\n<\/ul>\n<p>With so many iterations and inefficiencies, purchasing and incorporating a new tool in a line is not only costly but also delays the production process [4].\u00a0 Through utilizing in-house additive manufacturing to develop tools, Volkswagen Autoeuropa has eliminated the need to rely on outside suppliers and has drastically reduced the lead time between iterations.<\/p>\n<figure id=\"attachment_29238\" aria-describedby=\"caption-attachment-29238\" style=\"width: 300px\" class=\"wp-caption aligncenter\"><a href=\"https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic2.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-29238 size-medium\" src=\"https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic2-300x198.jpg\" alt=\"\" width=\"300\" height=\"198\" srcset=\"https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic2-300x198.jpg 300w, https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic2-768x506.jpg 768w, https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic2-1024x675.jpg 1024w, https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic2-600x395.jpg 600w, https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic2.jpg 1258w\" sizes=\"auto, (max-width: 300px) 100vw, 300px\" \/><\/a><figcaption id=\"caption-attachment-29238\" class=\"wp-caption-text\">VW Europa Printers<\/figcaption><\/figure>\n<p>Additive manufacturing is the process of joining materials to make objects from 3-D model data [5]. This proves to be a huge advantage over traditional manufacturing when dealing with customized parts as computer-aided design (CAD) software can be easily modified to incorporate lessons learned in practice.\u00a0 With this in mind, Volkswagen Autoeuropa has modified their process for developing tooling to the following:<\/p>\n<ul>\n<li>In-house production engineers and CAD technicians work to design tool.<\/li>\n<li>CAD models are sent to printers (which are located alongside the assembly line).<\/li>\n<li>Tools are printed overnight.<\/li>\n<li>Crew incorporates tools into production line the following day. Throughout the day, crew communicates areas for improvement to CAD technicians.<\/li>\n<li>CAD model is modified to address shortcomings and new tool design is sent to printers.<\/li>\n<\/ul>\n<p>As can be seen, this \u201cjust in time\u201d method of production allows for newly designed tools to be immediately tested.\u00a0 \u201cNow we have way more tools, with better fit and for far less money.\u00a0 The timings and cost to produce tools led us to a fast ROI, better product quality, and satisfaction throughout the entire process \u2013 from development stages to the final product,\u201d said Luis Pascoa, Pilot Plant manager at Volkswagen Autoeuropa [6].<\/p>\n<p>Through the reductions in lead time, respective cycle times, and cost required for each tool, Volkswagen Autoeuropa has realized an estimated \u20ac200,000 in savings for 2017 [3].\u00a0 One example is the production of a window gauged (shown below) used to position the rear window.\u00a0 Historically, the tool would cost \u20ac180 per part and take 8 days to complete.\u00a0 Through utilizing in-house 3D printing, the gauge can now be produced in 6 days at a cost of \u20ac35 per part [7].<\/p>\n<figure id=\"attachment_29242\" aria-describedby=\"caption-attachment-29242\" style=\"width: 300px\" class=\"wp-caption aligncenter\"><a href=\"https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic3.jpg\"><img loading=\"lazy\" decoding=\"async\" class=\"wp-image-29242 size-medium\" src=\"https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic3-300x197.jpg\" alt=\"\" width=\"300\" height=\"197\" srcset=\"https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic3-300x197.jpg 300w, https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic3-768x505.jpg 768w, https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic3-1024x674.jpg 1024w, https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic3-600x395.jpg 600w, https:\/\/d3.harvard.edu\/platform-rctom\/wp-content\/uploads\/sites\/4\/2018\/11\/VW_Pic3.jpg 1258w\" sizes=\"auto, (max-width: 300px) 100vw, 300px\" \/><\/a><figcaption id=\"caption-attachment-29242\" class=\"wp-caption-text\">3D Printed Tool for Aligning Window<\/figcaption><\/figure>\n<p><strong>Volkswagen\u2019s Path Forward<\/strong><\/p>\n<p>As is the case for any product, additive manufacturing has its limitations.\u00a0 After purchasing the Ultimaker 2+ printer, Volkswagen Autoeuropa realized that they needed more capabilities including dual extrusion, which would allow them to produce parts with more complex geometries. \u00a0They dealt with this issue by upgrading to the Ultimaker 3, the most capable printer offered by Ultimaker [8].\u00a0 As an organization, Volkswagen should use the Autoeuropa group as an example and incorporate 3D printing at all production plants.\u00a0 If they are to do this, however, their printing requirements may exceed the capabilities offered by Ultimaker printers.\u00a0 To address the sustainability of additive manufacturing, Volkswagen should consider investing in a small 3D printing company.\u00a0 In doing so, they can have a say in the evolution of printers and ensure their needs are consistently met.\u00a0 Prior to committing to an action plan, Volkswagen must ask itself the following questions:<\/p>\n<ul>\n<li>Can Autoeuropa\u2019s approach to producing tooling be implemented at larger sites, such as the Wolfsburg facility which has roughly 74,000 employees?<\/li>\n<li>If they were to acquire a small 3D printing company, how might Volkswagen incorporate them into the production process?<\/li>\n<\/ul>\n<p>&nbsp;<\/p>\n<p>(Word count: 788)<\/p>\n<p>&nbsp;<\/p>\n<p><strong>References<\/strong><\/p>\n<p>1] \u201cVolkswagen\u2019s Worldwide Vehicle Production from 2006 to 2017\u201d, [https:\/\/www.statista.com\/statistics\/272050\/worldwide-vehicle-production-of-volkswagen-since-2006\/], accessed November 2018<\/p>\n<p>[2] \u201cVolkswagen Autoeuropa Celebra 25 Anos\u201d, [https:\/\/www.volkswagenautoeuropa.pt\/comunicacao\/relacoes-publicas\/media-kit\/press-releases\/25-aniversario-volkswagen-autoeuropa.pdf], accessed November 2018<\/p>\n<p>[3] Jackson, Beau \u201cVolkswagen Saves $160k in Tooling Costs Using Desktop FDM 3D Printers\u201d, 21 June 2017, [https:\/\/3dprintingindustry.com\/news\/volkswagen-saves-160k-tooling-costs-using-desktop-fdm-3d-printers-116640\/], accessed November 2018<\/p>\n<p>[4] \u201cVolkswagen Autoeuropa 3D Prints Manufacturing Tools to Save Thousands of Euros\u201d, 22 June 2017, [https:\/\/www.engineering.com\/3DPrinting\/3DPrintingArticles\/ArticleID\/14729\/Volkswagen-Autoeuropa-3D-Prints-Manufacturing-Tools-to-Save-Thousands-of-Euros.aspx], accessed November 2018<\/p>\n<p>[5] Choon Week Joel Lim, Kim Quy Le, Qingyang Lu, and Chee How Wong, \u201cAn Overview of 3D Printing in the Manufacturing, Aerospace, and Automotive Industries,\u201d July\/August 2016, [https:\/\/ieeexplore-ieee-org.ezp-prod1.hul.harvard.edu\/stamp\/stamp.jsp?tp=&amp;arnumber=7517429&amp;tag=1], accessed November 2018<\/p>\n<p>[6] \u201cVolkswagen Autoeuropa 3D Prints Manufacturing Tools to Save Thousands of Euros\u201d, 22 June 2017, [https:\/\/www.engineering.com\/3DPrinting\/3DPrintingArticles\/ArticleID\/14729\/Volkswagen-Autoeuropa-3D-Prints-Manufacturing-Tools-to-Save-Thousands-of-Euros.aspx], accessed November 2018<\/p>\n<p>[7] \u201cVolkswagen Autoeuropa 3D Prints Manufacturing Tools to Save Thousands of Euros\u201d, 22 June 2017, [https:\/\/www.engineering.com\/3DPrinting\/3DPrintingArticles\/ArticleID\/14729\/Volkswagen-Autoeuropa-3D-Prints-Manufacturing-Tools-to-Save-Thousands-of-Euros.aspx], accessed November 2018<\/p>\n<p>[8] \u201cVolkswagen Autoeuropa 3D Prints Manufacturing Tools to Save Thousands of Euros\u201d, 22 June 2017, [https:\/\/www.engineering.com\/3DPrinting\/3DPrintingArticles\/ArticleID\/14729\/Volkswagen-Autoeuropa-3D-Prints-Manufacturing-Tools-to-Save-Thousands-of-Euros.aspx], accessed November 2018<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Can Volkswagen shake-up the status quo and use additive manufacturing to break into the tooling industry?<\/p>\n","protected":false},"author":11904,"featured_media":29262,"comment_status":"open","ping_status":"closed","template":"","categories":[4102,3340,3463,4386],"class_list":["post-29247","hck-submission","type-hck-submission","status-publish","has-post-thumbnail","hentry","category-3dprinting","category-additive-manufacturing","category-automotive-industry","category-tooling","hck-taxonomy-organization-volkswagen","hck-taxonomy-industry-auto","hck-taxonomy-country-portugal"],"connected_submission_link":"https:\/\/d3.harvard.edu\/platform-rctom\/assignment\/rc-tom-challenge-2018\/","yoast_head":"<!-- This site is optimized with the 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