Specialization is required to realize all the benefits

As a manufacturer of smart industrial automation for the automotive and aerospace industry, you know both areas very well. Which synergies does Valiant TMS have at its disposal in these areas?
Advanced technologies and Industry 4.0 are driving operating efficiencies across industries. Valiant TMS has delivered solutions that have changed the way aircraft are assembled; from fully automated intelligent production cells to groundbreaking automated tooling such as our main landing gear loader, we continue to challenge the status quo. The automotive industry has been pushing the boundaries of automation for decades; today the aerospace industry is looking to increase production rates, drive efficiencies and improve quality. While production requirements are different from automotive, many of the concepts are aligned. We are seeing the rate of robot integration rise in aircraft manufacturing and Industry 4.0 technologies are being exploited in smart automation that provides full manufacturing traceability through connected systems.

The automotive industry is currently faced with lower sales. In which way can a smart production system absorb the shock of such developments or negative effects on the OEM?
Smart production systems are becoming the norm for the efficiency and data transparency they provide. IIoT (Industrial Internet of Things) has set the stage to change the way factories operate and how people work. IIoT helps maintenance managers predict the likelihood of future failures and determine factors that could impact uptime. This level of insight helps factories avoid high costs and lost time associated with unexpected failures. Technologies such as merged reality are proving invaluable not only in remote design reviews, but in virtual overlays where assembled tools can be validated against their digital twins. We’re starting to use digital technologies to substitute physical products to start engineering and design ahead of physical product availability. Virtual commissioning is allowing us to design and validate system controls and find bottlenecks that were traditionally discovered during the debug process on the plant floor. There are many more use cases for this technology, including ergonomics reviews, maintenance accessibility and remote troubleshooting.

How have relationships between Valiant TMS and manufacturers and suppliers been changed along with Industry 4.0?
We are constantly improving our processes to better serve our customers and better collaborate with our supply chain. Specifically, we have been expanding and optimizing the use of our PDM, PLM and ERP systems to build an ecosystem that allows us to execute our projects seamlessly. We’re also continuously exploring new use cases where Industry 4.0 technologies can improve our efficiencies and allow us to improve our customers’ experience with automation. To date, we’ve implemented several technologies such as virtual design and tool build reviews, tool adjustment with virtual sheet metal and virtual line walk-throughs using Microsoft HoloLens. We have also invested in a state of the art additive manufacturing lab where we work with our customers to identify suitable components that have a high rate of wear, optimize the design and provide our customers with 3D-printed, production-ready components at a fraction of the cost and time versus using traditional manufacturing methods. This keeps the production line running while saving tool manufacturing cost, lead time and decreases spare part inventory requirements.

Which products and solutions have been most successful at Valiant TMS over the last few years? Which of your developments have been most popular with manufacturers?
Many of our advancements have centered around the requirements that consumers are demanding from our customers. Automated production systems with multi-model, random run flexibility allow our customers to respond quickly to sales trends and support a future headed toward an increased level of on-demand customization to meet the unique preferences of consumers. Our experience in the integration of advanced joining technologies to support new materials and multi-material assemblies as well as our expertise in the art and science of hemming technology and vehicle framing have been key to helping our existing customers succeed as well as creating opportunities with new customers. In recent years, we have also developed industry-leading solutions for e-mobility production such as assembly and test systems for batteries, battery trays, electric motors and electric drive units in response to the growing demand for new energy vehicles.

Automatization in the factories of the future means, in a big part, digitalization. Are you developing exclusively on your own or do you tap into the knowledge and know-how of external companies?
The very nature of Industry 4.0 promotes collaboration through connected systems. We believe now more than ever that partnering with leading companies that specialize in advanced technology provides the efficiencies required to deliver automation systems on time and on budget with the quality our customers expect. Systems are becoming more and more complex and specialization is required to realize all the benefits.

Are the demands of OEMs very different, internationally, or are we on the path towards unified standards?
Vehicles are evolving, presenting new production challenges. Lightweight steel, aluminum, magnesium and composites are trending in vehicle design to reduce emissions and improve fuel economy. Modular platforms reduce costs, but can’t stand in the way of innovative function and distinctive styling. Safety, durability and comfort have always been consumer expectations and now technology is playing a larger role than ever. It’s our responsibility as a system integrator and technology partner to develop efficient and effective production methods that align manufacturing with product evolution and bring vehicles to life exactly as designers and engineers imagine them. External pressures such as complexity and cost, diverging markets, environmental sustainability and the accelerating shift to digitalization are forcing expensive development for which no OEM was fully prepared. We believe that we will see an increased level of unified standards, shared platforms and technologies as OEMs face financial pressures and time-sensitive market demands.