The production line has been carefully designed to manufacture the Ibiza model, including the 3-door, 5-door, and the ST family version. This manufacturing process is carried out semi-automatically, using geometry tools that allow the parts to be assembled and, by means of different joining techniques, form the complete vehicle assembly.
To guarantee manufacturing efficiency and quality, robotized welding, adhesive and screw applications are used. These automated applications ensure a solid and precise assembly of the different parts of the vehicle, creating a perfect assembly.
In addition, an automatic tool change system per model has been incorporated, providing great flexibility in production. This allows the production line to be quickly adapted to the specifications of each Ibiza version, thus streamlining the manufacturing process, and optimizing the available resources and creating a seamless flow.
The challenge set was to achieve maximum productivity on the assembly lines, ensuring the quality of the final product and preserving a safe environment for workers in an automated work process.
A solution was proposed that consisted of carrying out a study and development of viable and efficient production processes. In addition, we worked on creating an optimized layout adapted to the available space according to the client’s needs. Finally, off-line simulation was used to guarantee the effectiveness of automatic and robotic production processes.
The execution of the project consisted of the design and manufacture of the production means for pre-series parts and final quality control of the product, under the quality standards required by our client. The installation and start-up were carried out by expert and multidisciplinary teams, trained in the client’s own standards.
Aeronautical tooling design is a key stage in ensuring precision, safety and reliability in the manufacture of large aircraft structures. In this article, we explore the sector’s main technical challenges —from rigidity and tolerances to material selection— and the opportunities opened up by technologies such as additive manufacturing, artificial intelligence and continuous improvement in engineering.
