Estimating quality costs in an automotive stamping plant through the use of simulation

The pressures of modern manufacturing require that the quality-cost benefits are determined when evaluating new procedures or alternative operating policies. Traditionally, cost reports and other quality metrics have been used for this purpose. However, the interactions between the main quality cost drivers cannot be understood at the superficial level and the effect that a new process or an alternative operating policy may have on quality costs is difficult to determine. An alternative to the traditional costing methods is simulation. The current work uses simulation to evaluate quality costs in an automotive stamping plant where the quality control is determined by operator inspection of their own work. Self-inspection quality control provides instantaneous feedback of quality problems, allowing for quick rectification. However, the difficult nature of surface finish inspection of automotive panels can create inspection and control errors. A simulation model was developed to investigate the cost effects of inspection and control errors and it was found that inspection error had a significant effect in increasing total quality cost, with the magnitude of this increase dependent on the level of control. Further, the simulation found that the lowest cost quality control policy was that which allowed a number of defective panels to accumulate before resetting the press-line.

An investigation of industry-wide emarketplaces in the Australian automotive industry

Covisint, a global, industry-wide eMarketplace in the automotive industry, has received considerable literature attention since its inception some four years ago. Despite predictions that it would transform the industry, it has made little impact on automotive markets in countries where its progress has been documented. A lack of literature concerning Covisint use in Australia makes understanding the Australian situation quite difficult.
This study addresses this deficiency by investigating several Australian automotive organizations and their application of Covisint in conducting supply chain trading with their business partners. The research found that the application of Covisint is significantly less than its potential.

Automotive can network response time analysis with variable jitter

Many methods to calculate message latencies for Controller Area Network (CAN) have previously been presented based upon the static worst-case behaviour of the system. With the use of modern simulation tools however, the behaviour of CAN networks can be simulated dynamically in order to find the likely worst-case response times for CAN messages. This paper shows the development of an automotive body control network model to be used as the basis for further simulations. A method to simulate the Worst-Case Response Time of this model is then presented, taking into account random queuing jitter.

Robust video/ultrasonic fusion based estimation for automotive applications

We describe how object estimation by a stationary or a non-stationary camera can be improved using recently-developed robust estimation ideas. The robustness of vision-based systems can be improved significantly by employing a Robust Extended Kalman Filter (REKF). The system performance is also enhanced by increasing the spatial diveristy in measurements via employing additional cameras for video capture. We describe a normal-flow based image segmentation technique to identify the object for the application of our proposed state estimation technique. Our simulations demonstrate that dynamic system modelling coupled with the application of a REKF significantly improves the estimation system performance, especially when large uncertainties are present.

Robust video/ultrasonic fusion-based estimation for automotive applications

In this paper, we use recently developed robust estimation ideas to improve object tracking by a stationary or nonstationary camera. Large uncertainties are always present in vision-based systems, particularly, in relation to the estimation of the initial state as well as the measurement of object motion. The robustness of these systems can be significantly improved by employing a robust extended Kalman filter (REKF). The system performance can also be enhanced by increasing the spatial diversity in measurements via employing additional cameras for video capture. We compare the performances of various image segmentation techniques in moving-object localization and show that normal-flow-based segmentation yields comparable results to, but requires significantly less time than, optical-flow-based segmentation. We also demonstrate with simulations that dynamic system modeling coupled with the application of an REKF significantly improves the estimation system performance, particularly, when subjected to large uncertainties.

Computer aided ultrasonic thickness strain analysis of automotive sheet metal stampings using FEA information

This paper discusses a computer-aided methodology for thickness strain analysis (TSA) of sheet metal stampings using geometry and strain information that is extracted from finite element analysis (FEA) results. The system utilises both FEA results and an ultrasonic gauge capability expert system to assist press shop personnel, providing them with capabilities such as optimum measurement point location and an estimate of gauge error. Key advantages of this enhanced TSA methodology are related to overall efficiency and accuracy gains.