Service

OUR SERVICE

WHAT WE DELIVER TO YOU

PRODUCTION DESIGN

To guarantee a safe and professional Production Design AdvaTec performs specifications, feasibility studies, operational planning and equipment
recommendations. 3D-CAD Robot programming, simulations and constructions by AdvaTec provide the production processes already in the digital facility.

SAFE PLANNING

Feasibility Analyses

Process feasibility of new installations – Reachability window definition, Prevention of collisions – Cycle time goals – Weak point evaluation

Planning of new Production Facilities

Feasibility studies – Installation and dimensioning of cycle time – Development of safety concepts – Determination of ideal skid design – Evaluation of profitability – Requirements specification and invitation to bids – Neutral comparison of offers – Benchmarking

Operation Planning

Project planning and management – Design of experiments – Planning of pre trials – Material flow simulation – Planning of new processes – Capacity planning

OFFLINE PROGRAMMING

Offline-Programs (OLP) for Robots & Application

High quality car body and parts programming (e.g. painting, EC, EMU, sealing, flaming, water cutting, bonding, quality and positioning control) – Variant and repair programs – Programs for breakdown concepts – Sequencing and dimensioning of all process parameters – Programs of highest quality for lowest material consumption, shortest cycle time and minimum machine load

Simulations in 3D-CAD

Robot sequences, Coating processes – Collision checks, Material flows, Cycle time calculations, Complete line processes – Reachability and weak spot analysis

3D-CAD Constructions

Development of installation layouts in 3D-CAD – 3D documentation for measuring concepts – Design of installation components and equipment in 3D-CAD – Conversion of 3D-CAD data – User oriented instruction material – Skid design, Parts positioning

PRODUCTION INTRODUCTION

AdvaTec Projects imtroduces fast and high quality production process with efficient trial and professional system parametrizations. The commissioning service of Advatec includes robot programming, implementation of new processes and acceptance checks.

PROCESS PREPARATION

Trials and Tests

Efficient and systematic execution of tests – Managing or supporting trials – Evaluation of measurement devices and procedures – Qualification and material qualifying examination – Precise test documentations – Scientific test data evaluation and correlations – Revealing of problem factors

System Parametrisation

Parametrisation of digital process monitoring systems – Setup of systems for part identification, failures quality control and different online measurements – Production Parametrisation (e.g. application or process engineering) – Parametrisation of special measurement devices and measuring methods – Dryer adjustments

COMMISSIONING

Commissioning Service

Production implementation of new robot- and machine programs – Implementation of measurement devices and measurement operations – Characterisation and root cause analysis of application failures – Process roll-out and production monitoring – Implementation of new processes and materials – Improvement of application capability – Special measurements with AdvaTec methods (e.g. air flow conditions, robot dynamics, booth geometries, part positioning)

Acceptance Checks

Safety checks and operational sequence safeguarding – Machine capability evaluations (MFU) – Process capability evaluations (PFU) – Acceptance of conveyor, process, application, measurement and robot techniques – Management of snag lists and check lists – Documentation and reports

PRODUCTION OPTIMISATION

The experience and methods of AdvaTec Projects improves production efficiency in terms of Costs, Quality increase, cycle time reduction and saving of material and ressources.

QUALITY IMPROVEMENTS

Quality Optimisation

Colour, Gloss, Appearance – Layer thickness of surfaces, edges and wrap-arounds, Substrate-Layer adhesion – Corrosion resistance – Surface hardness, Material properties

Installation Optimisation

Purge programs, Colour changes – Booth, Anode current, PT & ECoat – Filter, EMU, Dryer, Oven – Scrubber system, Air flow conditions – Disinfection and hygiene improvement

Robot Program Optimisation

Reduction of machine load – Reduction of fault liability – Elimination of application failures (e.g. in painting: pin holes, inclusions, agglomerates, orange peel, haze, cloudiness, runner, thin paint, colour failures) – Weak spot elimination – Coating Parametrisation – Motion sequence and safety spaces – Optimised utilisation of existing process windows

COST REDUCTION

Increase of Capacity (First run and quantity)

Cycle time optimisation – Reduction of installation down times – Reduction of dead times and secondary times – Process window extension – Elimination of quality failures – Optimised skid design concepts – Localisation and reduction of dirt sources

Saving Resources (Materials and working time)

Reduction of material consumption (e.g. paint, rinsing agent) – Increasing first run – Improvement and acceleration of operating processes – Reduction of overspray – Identification and realisation of possible savings – Reduction of handling times in case of installation and process failures – Reduction of rework – Increasing the application efficiency – Reduction of energy consumption

PRODUCTION SAFEGUARDING

The service and methods of AdvaTec Projects ensures sustaninability and safeguarding of the production process by introduction of new methods and process control systems. Transfer of Know how from AdvaTec to the customer is achieved by training, instruction documentation, installation of safeguarding process control systems.

PROCESS CONTROL

Introduction of Methods

Implementation of safeguarding concepts – Statistical process control – Quality management systems – Implementation of automated factory control processes – Design and implementation of individual tools for safeguarding process steps – Paint supply monitoring

Process Control Systems

Automated process diagnosis – Introduction of systems for failure detection and positioning correction – Design and upgrading of measurement devices – Generation of representative process data – Implementation of diagnosis systems

KNOW-HOW

Training on the Job

Teach-In robot programming – Online robot programming (3D Onsite, Shopfloor, RobotStudio, Roboguide, …) – Offline robot programming (RobCad, Process Simulate, modified RobotStudio, …) – Paint process Parametrisation (e.g. EcoScreen, Robview) – Programming of application parameters – Contour programming of machines – Course of instruction for production programs – Approaches for quality optimisation – Operation and parametrisation of process diagnostic systems, vision systems and new measurement systems – Facility and paint process analysis

Education

Basic and special know-how of paint processes, measurement, robot and application techniques – Overview of possibilities for process diagnosis, vision and intelligent quality systems – Feedback discussions – Tailor-made instruction material

WANT TO WORK WITH US?

You have a Project or challange we can help with? Please feel free to contact us.