SAR, together with partner FFT EDAG, received the order to re-engineer the main framing lines of the 6- and 7- series at BMW Plant 2.4 in Dingolfing and relocated it to another production hall.
Critical within this project was the short time window of just six weeks on the one side and the complexity of the re-engineering due to the complete removal of the 7-series production components on the other, which could have caused a complete loss of production of the 6-series.
 
The largest change done at BMW so far in relation to the time frame, necessitated a round the clock change of 70 robots as well as 8 PLC's together with a laser cabin for roof welding.
 
During this change, some of the robots got completely new functions. For example, one handling robot from a side frame station was moved to a loading station of floor groups and put on a seventh axis.
 
Generally, even new functions were done by so called re-tooling, so that old scanners, robots, etc. from other lines were re-used.

3D planning of the change

Previous setup

Goal of the change

The robots were measured up, by means of a measuring arm, in relation to the tools and jigs before the re-location as well as after the re-location. The resulting deviation was corrected offline and the remaining maximum deviations of 2mm (3D) adjusted online.
 
BMW was very satisfied with SAR and FFT, for their mastering of this challenge. The clearing up of the system of a complete vehicle type (7-series) with the resulting space saving was hailed a resounding success
 
For more information please contact aut@sar.biz