Introduction
A well-known OEM from southern Germany wanted to plan the processes involved in assembling bumpers and rear ends on the vehicle body to ensure a product design in line with the assembly process for new vehicle derivatives. As well as ergonomic use of handling equipment, this also requires a pre-assembly process linked into the cycle.  

The planning work was assigned to the Industrial Engineering team which qualified for the job on the basis of its extensive know-how and specific knowledge of this field.

Solution: Process planning for assembling the rear end module for premium vehicles, incorporating best-practice solutions.

Puncture points

• Planning the investment budget
• Production of project schedules and monitoring deadlines
• Influence of design and construction in terms of ease of assembly and safeguards against human error
• Planning assembly concepts to achieve the joining goals
• Validation both virtually and in hardware
• Definition of planned times, synchronization and the writing of operating instructions
• Procurement of all special equipment, screw systems and screwdrivers
• Development of adjustment concept for rear end using adjustment fixtures / gauges for setting the rear deck, rear lights, rear bumpers and bumper guide
• Invitation to tender for pulling tool for rear deck closing bracket and for handling device for towbar

Benefits
The assembly process for the "rear end" module was designed to allow for easy assembly and with as few joining goals as possible. Optimizing the process in line with the defined goals also enabled product quality to be enhanced and additional customer benefits to be generated.

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