Established in 1970 with a mission to manufacture the world’s best forest machines, Ponsse Plc., a Finnish company, is a global pioneer in the forest machine industry. With a 40,000 sq. m. (430,000 sq. ft.) factory in Vieremä, the company specializes in the sales, service, manufacturing, and technological development of environmentally-friendly cut-to-length forest machines. Ponsse employs over 1,800 people, operates in 40 different countries, and manufactures a wide range of harvesters, forwarders, and other machines. 

With innovation as one of its core values, Ponsse is committed to advancing sustainable forestry through continuous improvement of products, services, and processes for customer success. This has resulted in the creation of modern forest machines and a growing number of satisfied customers. To meet customer demand, Ponsse manufactures around 1,000 machines per year and commissions approximately one new robot station annually.

Boosting productivity with robotic welding and offline programming 

In challenging production environments, welding automation is essential to increase productivity. Recognizing this, Ponsse has always prioritized the improvement of welding processes in its production development. This understanding led them to implement robotic welding more than 15 years ago. Heikki Selkälä, Production Development Manager at Ponsse, shared that their goal is to robotize all basic welding, as part of their broader initiative to automate as many processes as possible, with a particular emphasis on welding.

When Ponsse incorporated robotic welding into their operations, they encountered difficulties because of the complexity and time-consuming nature of robot programming. The programming was carried out online using a teach pendant, requiring the robot to be inactive for a two-week period until the programming was finalized. This pause in operation had significant cost consequences, as it could potentially cause delays in the manufacturing process. 

To address these challenges and significantly reduce robot programming time, Ponsse needed a partner with the expertise and understanding of offline programming. The solution combines the offline programming expertise of Delfoi Robotics, now Visual Components Robotics OLP, with the powerful Visual Components platform. 

Today, 80% of the equipment are welded by robots. Our partner for offline programming of these robots has been Visual Components since the beginning. The cornerstone of our common growth story has been the continuous development of Visual Components software to meet our needs. Their process expertise has developed considerably, and we have always been able to rely on their agile way of working.

Heikki Selkälä, Production Development Manager, Ponsse 

Ponsse sets high standards for its production processes and expects the same level of customer-centric, long-term commitment, and reliability from its partners. Visual Components Robotics OLP, previously known as Delfoi Robotics, has been fulfilling these requirements for over 15 years. 

Enhancing automation utilization for continuous production 

With the help of Visual Components Robotics OLP, despite Ponsse’s highly demanding production processes and complexity of the robot programs, the programs can be completed within one day. The programs consist of Yaskawa robots performing the welding of forest machine frames, including several curved welds and welds within frame structures. 

The benefits of offline programming are realized everyday. As a key benefit, I see that offline programming makes things much faster and easier when robot programming can be done outside of production system without stopping production. Before, we had to make the necessary adjustments during the weekend before the production continued on Monday. Instead of the ten days that programming previously took, now the programming can be completed in just one day.

Asko Haataja, Head of Robotics Team, Ponsse

Improving weld accessibility to maximize productivity

In addition to offline programming, Ponsse uses the robot programming and simulation software to evaluate weld design for practicality, weldability, and accessibility. By testing weld design in conjunction with product development, the manufacturer ensures that the welding process is efficient and can reach difficult areas. This helps maximize the proportion of robotic welding relative to manual welding. 

During online robot teaching, there are scenarios where “hidden spots” in the welded parts are not visible to the operator and therefore require manual welding. However, with offline programming, the operator can view the product in the CAD model, enabling the welding of internal, hidden areas with a robot. This significantly increases the degree of automation and accelerates the entire production lead time by dramatically reducing the need for manual welding.

The customizability and the features of Visual Components Robotics OLP have been excellent for our needs. The visual platform is practical and the code can do things that would otherwise require manual operation. When the need is to weld with multi-axis portals, an ordinary software company could not serve us. Especially in these matters, Visual Components’ flexibility and agility brings us benefits that we value.

Heikki Selkälä, Production Development Manager, Ponsse

Visual Components Robotics OLP is utilized not only when introducing new products but also in refining existing programs, reflecting Ponsse’s commitment to continuous development. 

Streamlining robotic station design and calibration of multi-robot brands  

When planning for new robot cells, Ponsse uses Visual Components from the robotics concept design to ready-to-go robot programs. The design of new robot layouts is an iterative process, during which Ponsse uses Visual Components as a layout design tool. This tool helps define the optimal layout for a specific robot configuration and the products to be manufactured in the robot cell. The all-in-one Visual Components Robotics OLP, being universal and compatible with all robot brands, supports Ponsse’s use of multiple industrial robots from different manufacturers. 

When the design of a new robotic welding station starts, we will model a digital replica of the station with software and test the welding possibilities of the parts. Once the investment decision has been made, I will contact Visual Components and we will continue to complete the planning.

Asko Haataja, Head of Robotics Team, Ponsse

The advanced simulation capabilities of Visual Components Robotics OLP enable accurate validation of robot programs prior to their deployment in production. The final stage of new robotic station implementation, known as commissioning, involves calibration of the designed robot cell for accuracy, ensuring that the programs function accurately for a faster production ramp up. Ponsse has several Yaskawa and ABB robot stations, all of which are programmed offline.

A good example of Visual Components’ agile operations and rapid response is how they developed remote calibration for offline programming during these exceptional circumstances in recent times. In particular, they don’t have to be physically present here at the factory to advise us when the calibration of the robots can be done virtually from anywhere.

Asko Haataja, Head of Robotics Team, Ponsse 

Ponsse’s partnership with Visual Components has resulted in significant time savings, improved productivity and automation utilization, streamlined robotic station planning with faster and easier robot programming. This case study exemplifies how Ponsse, a global leader in forest machines, has harnessed innovation and productivity with Visual Components Robotics OLP to stay ahead of the competition in the industry. 

About Visual Components

Founded by a team of simulation experts and amassing over 20 years in business, Visual Components is one of the pioneers of the 3D manufacturing simulation industry. The organization is a trusted technology partner to a number of leading brands, offering machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production processes and offline robot programming (OLP) technology for fast, accurate, and error-free programming of industrial robots.

Want to learn more about the benefits of our solutions for your business? Contact us today!

The post Ponsse is driving forest machine innovation and improving productivity with Visual Components Robotics OLP appeared first on Visual Components.

Since the implementation of Delfoi Robotics (now Visual Components Robotics OLP), our parts are more consistent as well as the repeatability of welding has improved significantly. We have more time improving welding and other systems because of the time saved by not needing to do manual programming and touch ups on the programming. Delfoi Arc has proven to be a very versatile software, our robot systems have seam tracking functionality, Delfoi was able to implement the macros for the seam tracking. With the assistance of Delfoi Robotics’ counterpart Apexiz the commissioning could be done with great precision,

Ferdi Beukes, Mechatronic Engineer at Afrit

Delfoi’s robot offline programming has improved the quality furthermore and streamlined the processes. Time savings have been significant though the software has been in use only a relatively short time.

Our engineers say that manual programming man work hours have been reduced by 80% and programming time reduced by 60%, from two weeks manual to four days offline, and we have increased our output of 8 bins a day to between 16 and 20 bins a day. 

Gerhard van der Walt, Continuous Improvement Manager at Afrit

Examples of improvements:

• Manual programming man work hours reduced by 80%

• Programming time reduced by 60% (from 2 weeks manual to 4 days offline)

• Production lead time improved by 62% for not being required to do manual programming

• Number of parts lost by manual programming reduced from 60 to 0 (each part consists of ±120m of welding)

Commissioning and calibration of this AFRIT’s robotic cell were done by Delfoi Robotics’ partner in India, APEXIZ.

We are sure that the programming time will be further reduced after they get more experienced. Features such as cloning, multi-layer, automatic axes optimization, vision system integration, templates and weld databases allows the users to increase their productivity enormously, especially in big systems such as AFRIT’s. For us it is very important that the user is confident to copy and run the programs created offline without any touch-up and we are able to achieve it using Delfoi Arc

Hari Nidamarthy, the founder of APEXIZ

About AFRIT

AFRIT is one of the most respected and innovative trailer manufacturers in Africa. With more than 50 years of experience in the industry and a product built on a constant drive for optimization and innovation, they remain the number one choice for customers who are looking for a more efficient payload and a high return on investment.

About APEXIZ

APEXIZ offers digital manufacturing solutions such as 3D simulation and robot offline programming. APEXIZ and its partner companies have many years of experience in developing simulation and robot offline programming software.

About Delfoi Robotics

Delfoi Robotics is a pioneer company and trailblazer in offline robot programming worldwide and a world-class expert in production simulation and production scheduling and execution. As of October 2022, Delfoi Robotics is a part of the Visual Components Group.

The post AFRIT production runs faster than ever, thanks to Visual Components Robotics OLP appeared first on Visual Components.

We have developed a solution that is able to use the same equipment for many different items and in the fall we will start production with a pilot project. We will work with a robot cell and use the Delfoi Robotics (now Visual Components Robotics OLP) offline programming system

Erik Åstrand, a specialist in welding optimization at Volvo CE

”Jigless” welding

The pilot project will focus on the manufacturing of components for Volvo’s dumpers in Braås. The optimization involves introducing ”jigless” welding in production, i.e. welding is carried out using flexible robots instead of customized jigs or fixtures. Erik mentioned,

In the robot cell, we have a handling robot and a welding robot that build the items together. The handling robot picks up and places the different parts while the welding robot welds them together and then we continue a bit at a time until the item is complete.

Mainly, it is about items up to about 60 kilos, but in the long run, the concept can also be an integral part in the production of major components such as vehicle frames. Maximum manufacturing flexibility also requires the fast creation of programs when the robots weld a new item. There, Delfoi Robotics’ offline programming system plays a key role.

Offline programming

Offline programming means that the robots are programmed in a computer environment without disturbing the process. This reduces the number of production stops and reduces production costs. Delfoi Robotics is the world leader in the field of welding, which made them an obvious choice of supplier. About Delfoi Robotics, Erik concluded,

We wanted the best technical solution and software that is compatible with as many robot brands as possible. Delfoi’s system is very visual and intuitive to program.

The robot cell in Braås will be used for 30 low-volume items in a continuous one-piece flow without any set times. If the pilot project goes well, the plan is to apply the same manufacturing principle to more products and other Volvo CE plants.

The post Volvo construction equipment invests in smart manufacturing in a new pilot project appeared first on Visual Components.

AGCO is one of the world’s leading manufacturers of tractors, combines and other agricultural machinery sold under well-known brands such as Fendt and Massey Ferguson. The Fendt plant in Asbach-Bäumenheim, Bavaria, produces driver cabins for tractors and self-propelled harvesting and crop protection machines. Nearly 1,200 employees manufacture, weld, paint and assemble cabins of various designs at this facility. Fendt cabs for tractor assembly are delivered Just-In-Time and Just-In-Sequence, i.e. the parts are built in the same sequence as they are needed on the assembly line at the Fendt plant in nearby Marktoberdorf.

The essential part of a driver’s cabin is a structure made of bent and welded tubes. The tubes are automatically supplied from a storage system and fed to a laser cutter. The tubes are then passed on to bending machines, loaded and unloaded automatically by robots. As the last step before welding, the tubes are cut to their final contour by a 3D laser; this is also done automatically. After this, the tubes are welded together to form the cabin frames. The latest welding technologies and innovative welding robots are used for this. Thanks to precise cutting and modern welding processes, it is possible to manufacture ergonomic cabins with curved windscreens.

AGCO’s engineering department is responsible for process optimization and procurement of manufacturing equipment. They wanted to optimize robot sequences and make improvements to individual cells in the tube processing workflow. The tubes are processed by a total of six interlinked systems with a high degree of automation. Previously, to carry out such investigations and evaluate possible improvements, production had to be stopped, which resulted in high costs. Therefore, the engineering department looked for a better alternative.

It was decided to model the rather complex production equipment and workflow as a digital twin. The digital twin improves processes, optimizes the production cells and simulates the improved workflows. The digital twin also provides a basis for discussion for future optimizations, in case further activities in a cell should be carried out by the robot.

AGCO’s manufacturing engineers found the solution in the 3D factory simulation software from Finnish solution provider Visual Components. Visual Components simulation can be used to design and optimize complete manufacturing systems, including offline programming of robots. The software simulates the entire manufacturing process and the smooth cooperation between robots, laser cutting and tube bending machines. The simulation allows non-productive times to be minimized and issues such as robot accessibility and collision avoidance to be investigated.

The result of the simulation was very satisfying. For example, we were able to carry out reachability studies on some equipment that we previously couldn’t have done without a production stop. And we were able to realistically analyze the cycle times that could previously only be estimated.

Norbert Pritzl, AGCO

Norbert Pritzl from AGCO, who was responsible for the project, says: “In the first step, it was not important to model all the systems in every detail. Important were only those machines that we thought needed to be modified. The result of the simulation was very satisfying. For example, we were able to carry out reachability studies on some equipment that we previously couldn’t have done without a production stop. And we were able to realistically analyze the cycle times that could previously only be estimated”.

The project was gradually expanded as AGCO’s engineers learned more about the possibilities of the Visual Components software. They started with a small area that they wanted to optimize and gradually rolled out the simulation across the entire automated equipment. And in the future, other areas of manufacturing will also be optimized with Visual Components’ simulation solution.

When introducing a new software solution, it is usually expected that dealing with the yet unknown tool will pose a certain challenge. But not in this case, because the good communication and training received from Visual Components service department helped the employees a lot.

The extensive component library supplied was also immensely helpful: almost all the robots and other equipment used in the pipe bending, cutting, and welding process were already available in the library. If components were not available, they were either improvised or modeled in the CAD system and then imported to Visual Components. It is very helpful here that Visual Components has interfaces to a large number of CAD systems.

“With Visual Components, we can run through scenarios in our production process that previously could only be accomplished with a production shutdown and through extensive testing on the production line,” says Pritzl of AGCO. “This also allows us to accurately model and simulate new concepts so that we can use them to obtain quotations, for example from equipment manufacturers. This saves us a lot of time in project management. In the past we had to try to reach a common consensus with many on-site meetings, elaborate presentations, and detailed descriptions. Visual Components makes it much easier for us to communicate with international equipment manufacturers”.

With Visual Components, we can run through scenarios in our production process that previously could only be accomplished with a production shutdown and through extensive testing on the production line.

Norbert Pritzl, AGCO

The feedback within the company regarding the possibilities of Visual Components has been very positive; many employees in the engineering department have been waiting for such a tool. It is also a great benefit for the suppliers of production equipment, as they can understand more easily what the requested equipment is supposed to do.

Will AGCO continue to use Visual Components solutions in the future? Norbert Pritzl has definite ideas: “We will use Visual Components in other projects as well. We are currently working on projects such as a layout for a new welding hall and the optimization of assembly. We now can quickly and easily visualize and simulate an optimized concept. This will lead to many more projects and thus to further optimization in our production”.

The state-of-the-art automation in manufacturing guarantees the perfect quality of each individual tractor cabin at the highest level. Visual Components’ solution has played a major role in helping to manufacture cabins for tractors and other agricultural machinery with outstanding quality at competitive prices.

The post AGCO Case Study: We Help Put Enough Food on the Table appeared first on Visual Components.

In addition to custom and turnkey hardware solutions, Pemamek also develops and offers its own software, PEMA WeldControl, for the control and programming of PEMA robot welding solutions.

In this case study, we’ll show you how Pemamek uses their powerful software, PEMA WeldControl, as both an offline programming and sales tool for their robotic welding solutions, and why they chose to build the software on the Visual Components 3D manufacturing simulation platform.

The Birth of PEMA WeldControl

Prior to developing PEMA WeldControl, Pemamek used other commercial simulation software for both their own purposes as well as to offer their customers for offline programming (OLP) of their robotic solutions. However, as their competition became more global, and competitors began offering turnkey hardware/software solutions, Pemamek realized this put them at a disadvantage.

“We are in a highly competitive market, and it’s essential that we offer our own OLP tool in order to be competitive for projects,” said Teemu Rusi, PEMA Robotics Team Leader.

The company made the decision to develop their own OLP software, which they called PEMA WeldControl.

“The origin of our WeldControl software is actually in the shipbuilding industry,” said Teemu. “We developed a unique solution for camera vision-based programming for welding ship panel components. We wanted these features to be available in general fabrication as well, so we developed our own offline programming software with Visual Components as the 3D engine for it.”

WeldControl quickly gained traction and importance in PEMA for both its use as a sales tool and OLP solution that they could offer customers. The PEMA WeldControl product family now consists of 5 main products: WeldControl 100, 200, 300, 500, and 700. WeldControl 200 is Pemamek’s robotic welding solution for shipbuilding and WeldControl 300 is designed for heavy industry, both of which are built on the Visual Components platform.

Selecting a platform

In selecting a platform on which to build WeldControl, ease of use was one of Pemamek’s top criteria, from both a development and end-user perspective.

“The Visual Components platform offers good interfaces that allow us to develop the functions and features that we need and that our customers want,” said Teemu. “We’re constantly working to improve the capabilities and usability of WeldControl for our end users and the Visual Components platform gives us the flexibility to do this.”

Lasse Lahtinen, Product Manager for PEMA WeldControl agrees.

“Working with the Visual Components platform is very easy,” said Lasse. “The user interface is easy to understand and there are already many tools and features available for our purposes. The open programming interface and support for common programming languages make it easy for us to further customize and develop our applications.”

“Also, the component libraries in the public eCatalog, especially the robot models, are very comprehensive.”

Simulation performance was also an important criterion in selecting a platform, as some customer applications for WeldControl can be quite intensive. “Importantly for us,” said Teemu, “The 64-bit 3D engine has proven to be stable even in very complex configurations.”

Working with the Visual Components platform is very easy. The user interface is easy to understand and there are already many tools and features available for our purposes. The open programming interface and support for common programming languages make it easy for us to further customize and develop our applications.

Lasse Lahtinen, Product Manager for PEMA WeldControl

Simulation that drives sales of new systems while improving customer productivity

While the main purpose for Pemamek to develop PEMA WeldControl was to accelerate the commissioning and improve the productivity of their robot welding solutions, it quickly became their best sales tool.

“The biggest leap forward has come from the pre-sales phase, where Visual Components is a superior tool for convincing the customer how our robot welding solutions will meet their needs, such as fitting the layout, capacity estimations, and meeting production requirements,” said Teemu. “We can utilize our WeldControl offline tools for creating pre-sales material like simulations for the customer workpieces.”

The biggest leap forward has come from the pre-sales phase, where Visual Components is a superior tool for convincing the customer how our robot welding solutions will meet their needs, such as fitting the layout, capacity estimations, and meeting production requirements.

Teemu Rusi, PEMA Robotics Team Leader

“With WeldControl and Visual Components, we can quickly create sales materials such as 2D drawings and 3D simulations, which were previously very time-consuming tasks. Today, we regularly create these materials prior to the first customer meeting since it’s so fast and easy. It’s always good to visualize with them the planned layout or some certain described functions.”

With WeldControl and Visual Components, we can quickly create sales materials such as 2D drawings and 3D simulations, which were previously very time-consuming tasks.

Teemu Rusi, PEMA Robotics Team Leader

For Pemamek’s customers, the software is an important if not required component of their investment in robot welding systems.

“WeldControl software is a critical element in all robotized welding systems that we offer,” said Lasse. “It offers the offline programming and the system managing tool to the customer.”

“Our robotized systems for shipyards can’t be delivered without it. Our machinery customers don’t require it, but it’s strongly recommended to improve productivity.”

While not all Pemamek’s customers think OLP software is a necessary tool when exploring robot welding solutions, especially if it’s their first system, most of them quickly realize its value when introduced to WeldControl in the pre-sales phase.

“Our benefit in the sales is that our software is fully optimized with our hardware: we don´t need to compromise anything and we are also ready to implement special customer needs if needed,” said Lasse. “I believe that the total solution provided by Pemamek is the key factor in sales.”

It’s also during this phase when Pemamek’s customers see how easy WeldControl is to use.

“Many of our customers are able to have their welders and fitters perform the robot programming after a short basic training,” said Lasse. “This leads to a fast return on investment on the whole solution when the robot starts production right after the delivery.”

“It’s easy to use for individuals of all kinds of backgrounds. The software is visual and straight forward.”

A Roadmap for the Future

While Pemamek’s partnership with Visual Components started several years ago, the journey is only just beginning, and both companies are looking forward to what’s ahead. The key to the success of this partnership has been the smooth collaboration between the product development teams of Pemamek and Visual Components.

“Our experience from working with Visual Components has been very positive,” said Teemu. “They’re responsive to our needs and we know a lot of people inside the company.”

“The co-operation between Pemamek and Visual Components has been smooth and easy, and the communication is open,” added Lasse.

Looking ahead, Pemamek views PEMA WeldControl as an essential part of their overall product portfolio and plans to continue the development of the WeldControl product family.

“WeldControl shall be developed further,” said Lasse. “We have a roadmap for the years ahead, and we’ll be relying on Visual Components to further improve the capabilities and functionalities of the platform to help us to develop the software. I’m confident that our relationship with Visual Components will continue for a long time.”

Teemu agrees. “Visual Components is a superior tool that has enabled us to create user-friendly and fast tools to meet our customers’ demands. We look forward to continuing our partnership for years to come.”

Visual Components is a superior tool that has enabled us to create user-friendly and fast tools to meet our customers’ demands. We look forward to continuing our partnership for years to come.

Teemu Rusi, PEMA Robotics Team Leader

The post Pemamek Case Study: The Birth & Evolution of PEMA WeldControl appeared first on Visual Components.

With 14 factories, 55,000 employees and 2017 sales of EUR 8.9 billion, KONE is a global leader in the elevator and escalator industry. The Finnish-based company provides elevators, escalators and automatic building doors, as well as solutions for maintenance and modernization, which add value to the life cycle of any building. 

As KONE has grown over the years, so has the demand on their factories.

“A bit more than a year ago, we saw the need to change how we communicated with our stakeholders about assembly cells planning,” said Miikka Ahola, KONE’s Manufacturing Solutions Manager for KSU Manufacturing Solutions.

“New production processes are complex and difficult to explain via CAD and Excel, especially with robotics.”

Miikka and his team decided it was time to look for a solution that could not only help them with planning and designing new production solutions, but also improve their communication with stakeholders during the planning and development process.

“We were mapping potential solutions for simulation and layout planning for our factories and we wanted to have 3D layouts, as they help a lot in visualizing the layout and space requirements,” said Miikka.

“When looking for potential suppliers we found Visual Components software.”

After conducting an evaluation of potential software solutions, Miikka and his team decided to move forward with Visual Components.

Using Visual Components was a lot easier compared to other products we evaluated. That was very critical to us.

Miikka Ahola, KONE’s Manufacturing Solutions Manager for KSU Manufacturing Solutions

A truly global planning and development team

KONE’s global development and planning team has its headquarters in Espoo, Finland; however, it’s truly a big and global team, and extends to all 14 factories.

“We have a global development team responsible for technology and process development, which is supported by local teams in each factory, with their own development engineers,” says Miikka.

“Most of the line, process, and technology development is done by the global team, and implementation and fine tuning of the solutions is done in coordination with the local organizations.” 

All new R&D projects are first reviewed by the global team. They review the investments, technology, and manufacturability of projects in the first stage, then handover the product from R&D to production, and oversee implementation at KONE’s factories. 

“We work in the middle, making sure we have all the plans and investments done, and there is full readiness for production start-up,” says Miikka.

Integrating Visual Components into the planning workflow

For Miikka and his team, it was easy to incorporate Visual Components into their planning workflow.

“Typically, we use Visual Components in the early stages of new product implementation projects. This helps us to present our stakeholders with a clear image of what type of manufacturing station or line is needed, and how much space is required to hit production targets,” says Miikka.

New investment projects at the global development team typically begin with creating mock-ups of lines or stations.

“We start with defining what we are going to make and put together a mock-up layout that has all needed lines and assembly stations, but might not be defined according to specific product needs. This helps us to define the space requirements to start with,” says Miikka.

Once they’ve narrowed to a design they think will work, they move to create a layout.

“We start to fine tune the individual stations and improve the ergonomics,” says Miikka.

Next, they simulate the production workflow, validating production calculations and space requirements, and looking for optimization and cost saving opportunities. Having a visual tool to communicate these tradeoffs with stakeholders has been especially helpful for Miikka and his team.

We can visually show our stakeholders in R&D, product development, quality, and operations how changes in the design can reduce labor and equipment costs.

Miikka Ahola, KONE’s Manufacturing Solutions Manager for KSU Manufacturing Solutions

After getting management approval to proceed with the project, they use Visual Components export files, such as simulation videos, 3D PDFs, and 2D drawings, to facilitate communication with factories during implementation and deployment.

Working with suppliers to build out the eCatalog

As with many Visual Components users, Miikka and his team have found that having a large selection of components and layouts in their eCatalog makes it easier to start new projects.

“Having a big component library is must have, so that new projects can be easily started,” says Miikka.

To help them build out their eCatalog when they were getting started with Visual Components, Miikka and his team encouraged a system integrator they frequently worked with to provide KONE with models of equipment and layouts they’ve built or designed. This has given Miikka and his team reference layouts they can use to easily start new projects, allowed them to evaluate new equipment and solutions developed by the integrator, and improved their collaboration during the planning of new projects.”

“In this arrangement, both sides are benefiting,” says Miikka.

Through KONE’s partnership with their system integrator, Miikka and his team have a steady stream of components and layouts they can use in their development planning process. They’re also better informed about the latest production technologies and processes.

“We get a regularly updated library of components and layouts, to help us with our planning, and they get opportunities for projects at our global factories,” says Miikka

Having a big component library is must have, so that new projects can be easily started.

Miikka Ahola, KONE’s Manufacturing Solutions Manager for KSU Manufacturing Solutions

Improving productivity, reducing time to market

For Miikka, the greatest benefit Visual Components’ software brings to KONE is the time it saves on the development process. It facilitates faster decision making and more efficient communication with stakeholders. It also helps them to reduce time to market.

“Visual Components is helping us to start the manufacturing development process much earlier than before, and reduce critical time to market,” says Miikka.

Miikka and his team are juggling a lot of simultaneous projects, from planning new factories in India to testing future technology concepts; and Visual Components is helping them to be more productive so they can meet the rising demand for KONE’s products.

In the future, Miikka hopes to expand the use of Visual Components to their global factories.

“We plan to implement Visual Components to our factories, so that local development engineers can use it to highlight changes, ideas, and suggest lean improvements with simulations,” says Miikka.

Visual Components is helping us to start the manufacturing development process much earlier than before, and reduce critical time to market.

Miikka Ahola, KONE’s Manufacturing Solutions Manager for KSU Manufacturing Solutions

The post KONE Case Study appeared first on Visual Components.

Wärtsilä, a global leader in advanced technologies and complete lifecycle solutions for the marine and energy markets, was first introduced to Visual Components in 2008. Tero Kujamäki, Project Manager for Marine Solutions at Wärtsilä’s Delivery Centre Development (DCD), was working with the Seinäjoki University of Applied Science to create 3D simulations of an automated cylinder head assembly line with Visual Components software.

“We were planning a new cylinder head assembly line and wanted to create a simulation model of the process,” said Tero. “We used Visual Components to create a simulation video of the automated line and validate our calculations for capacity and phase time.”

As the strategic planning arm of Wärtsilä’s Delivery Centre Vaasa (DCV), the DCD is responsible for planning DCV production development activities over 5-10 year periods. They investigate new production technologies and plan major investments in new production centers.

Tero and his team had previously evaluated other manufacturing simulation software solutions, but found them too complex and resource intensive. For an organization that’s constantly exploring new production solutions, they needed a solution that could keep up with their fast pace; a tool that could quickly create and simulate production concepts, but also be used for more in-depth analysis.

“We were not just looking for a powerful tool to simulate robot activities,” said Tero, “But something that could simulate the entire production chain.”

“For this, Visual Components was the best tool.”

The experience with Seinäjoki University left Tero and his team convinced that Visual Components fit their needs. The simulation videos and layouts they created of the assembly line were very impactful (the investment recommendation was approved), and Wärtsilä began using Visual Components shortly after.

We were not just looking for a powerful tool to simulate robot activities, but something that could simulate the entire production chain. For this, Visual Components was the best tool.

Tero Kujamäki, Project Manager for Marine Solutions – Wärtsilä’s Delivery Centre Development

Optimizing the project lifecycle with 3D manufacturing simulation

The DCD initially used Visual Components to design layouts and simulations of production lines – investment projects being considered by Wärtsilä. As Tero and his team explored the capabilities of Visual Components, they started using it for more applications, including robot cell simulation, design analysis, and creating training materials.

Wärtsilä now uses Visual Components to support the complete lifecycle of new investment projects, from ideation and concept design to technical validation and implementation. The main benefits that Tero and his team have seen with Visual Components are improvements in production performance, communications, and implementation.

“As a project manager, about 90% of my job is communication,” said Tero. “That’s why Visual Components is the perfect tool for us. We can easily and concretely show the effects of design changes to the overall process, and share that information with both technical and non-technical people.”

As a project manager, about 90% of my job is communication. That’s why Visual Components is the perfect tool for us. We can easily and concretely show the effects of design changes to the overall process, and share that information with both technical and non-technical people.

Tero Kujamäki, Project Manager for Marine Solutions – Wärtsilä’s Delivery Centre Development

Achieving bottom line impact

10 years later, Tero and his team have seen positive results since first introducing Visual Components to Wärtsilä, specifically in the areas of production design and project implementation.

The production solutions Wärtsilä builds are highly automated and use advanced equipment and robotics. While the machines on their factory floors are state-of-the-art, prior to using Visual Components, Tero and his team knew their production lines weren’t optimally designed. They were able to squeeze much more performance out of production solutions designed with Visual Components, leading to projects with much more financially attractive returns.

Once a project is approved, there is intense pressure for it to be delivered and commissioned quickly. There are always implementation challenges with projects of this scope and complexity; but with Visual Components, the DCD saw an opportunity to accelerate the ramp-up period of new projects. Tero and his team used Visual Components to plan and coordinate implementation with project stakeholders, using layouts, 3D models, and simulations to communicate project timelines, milestones, and end-states. This resulted in shorter ramp-up periods, faster delivery times, and significant cost savings for Wärtsilä.

“Previously, we used 2D drawings or Excel spreadsheets to map and describe our processes, which wasn’t always easy for us to communicate to others,” said Tero. “We now use 3D models and simulations, which helps stakeholders more quickly understand our technical proposals, and saves us time from having to explain complex calculations.”

“Visual Components is now our standard when planning projects and processes.”

Visual Components is now our standard when planning projects and processes.

Tero Kujamäki, Project Manager for Marine Solutions – Wärtsilä’s Delivery Centre Development

Exploring the digital and virtual frontiers

Wärtsilä continues to work on exciting projects that advance their marine and energy production capabilities. The next big thing: factory digitalization. Tero and his team are exploring how to digitize Wärtsilä’s production operations. The DCD sees significant opportunity in factory digitalization, specifically with the ability to create a digital twin of their factories, to simulate changes and upgrades to production lines before deploying them. Considering the scale and complexity of their factories, Tero expects this would save Wärtsilä significant time and expense in planning and implementation of future projects.

“As production development is one of our key areas at the Vaasa factory, we have to explore new tools and methods that can help us take the next steps in all of our development areas,” said Tero. “Pre-digitalization has been an active development area for us the past 10 years and we understand the benefits for this quite well.”

“We already have a partial environment for factory digitalization that’s working, we now need to achieve integration between existing tools at scale.”

As an early user of Visual Components Virtual Reality (VR), Wärtsilä also sees a lot of potential in VR for their planning projects. In addition to being able to experience new production concepts in full-scale, Tero and his team are excited about how it will enable a much richer training experience, and how it can improve stakeholder engagement and collaboration on future projects.

“We’re excited about how VR will allow us to better support the end-users of our production solutions before they’re commissioned,” said Tero. “We think there’s great potential for training end-users and operators in a VR environment so we can further reduce ramp-up time for new projects.”

We’re excited about how VR will allow us to better support the end-users of our production solutions before they’re commissioned.

Tero Kujamäki, Project Manager for Marine Solutions – Wärtsilä’s Delivery Centre Development

ABOUT Wärtsilä

Wärtsilä is a global leader in advanced technologies and complete lifecycle solutions for the marine and energy markets. By emphasizing sustainable innovation and total efficiency, Wärtsilä maximizes the environmental and economic performance of the vessels and power plants of its customers. In 2016, Wärtsilä’s net sales totaled EUR 4.8 billion with approximately 18,000 employees. The company has operations in over 200 locations in more than 70 countries around the world.

The post Wärtsilä Case Study appeared first on Visual Components.

Fill GmbH is a global mechanical engineering and factory construction company from Austria. Since 2009, Fill has used Visual Components’ 3D simulation software to support its sales, production planning and engineering.

Before adopting Visual Components, the company went through an extensive review of 69 different simulation tools, ultimately choosing Visual Components due to its proven track record and excellent partner support.

Our customers’ first impressions of the simulations have always been above all positive.

Alois Wiesinger, M.Sc. (Tech.), Product Developer at Fill

3D Simulation – the implementation phase

During the nine-month implementation phase the project team created the first simulations and the parallel models for a standardized component library. While standard industrial components such as conveyors and robots could be taken from Visual Components’ component library, numerous special components were modelled individually by the partner DUALIS.

Already the first 3D simulations received a great response from Fill’s customers.

Simulation enables system optimization

Simulation benefits not only sales and marketing, but also the actual factory design. Simulation helps in optimization and especially in avoiding errors in advance.

A practical example comes from the wood processing industry. Initial calculations indicated an output of 500 planks per hour for the production line. However, the simulation showed that the output would actually be as few as 400 planks per hour as flaws in the drive reduced the feed rate.

Using simulation, the central bottleneck was identified. The project planners then optimized processes and increased the performance of some resources. In the end, an output of 500 planks per hour was achieved.

“It was only through the simulation and its realistic modelling of dynamic interactions that we were able to discover the weak points of the system at an early stage and ultimately meet the requirements to the complete satisfaction of all concerned.” says Alois Wiesinger.

As the example indicates, simulation can be an invaluable asset in reaching the goals for any production line.

It was only through the simulation and its realistic modelling of dynamic interactions that we were able to discover the weak points of the system at an early stage and ultimately meet the requirements to the complete satisfaction of all concerned.

Alois Wiesinger, M.Sc. (Tech.), Product Developer at Fill

The post Fill Case Study appeared first on Visual Components.