AUTOMOTIVE | SPAIN
FANDANGO
Operational efficiency
PROJECT OBJECTIVE
Three key industry challenges
The FANDANGO project focused on improving operational efficiency in the automotive components sector by addressing three key challenges: visibility of information throughout the supply chain, maximizing end-product quality, and optimizing processes that do not add direct value, such as maintenance.
The sector presented difficulties in the design of in-line quality control systems due to the high cadence of the manufacturing processes, the diversity of references and defects, as well as the particular conditions of the production line, such as the presence of lubricants, dirt, heat and lighting.
Estampaciones Mayo, a manufacturer of components for the automotive industry, led the FANDANGO project in consortium with other Spanish companies such as Álava Ingenieros, Grupo Antolín, Fersa Bearings, Segula, Tecnalia, IKERLAN, ITCL, Fagor and Eurohelp Consulting. The project received funding of 5.5 million euros through the National Business Research Consortia Program (CIEN) of Spain's Center for the Development of Industrial Technology (CDTI), aimed at industrial and experimental research projects in strategic areas with potential international projection.
Date of execution:
October 2018 - December 2021
Location:
Spain
Sector:
Automotive
Client:
How we made it happen
Predictive maintenance and sensorics
Álava Ingenieros was a key player in the FANDANGO project, participating in all phases of development. From the definition of use cases and technological solutions, through the development of hybrid models and digital twins, to technological validation and evaluation. Specifically, the company focused on ensuring the right conditions for optimizing in-line inspection, implementing condition-based maintenance and optimal quality process control, sensing and capturing real-time data from physical assets, and developing CAD matching models for new quality control solutions.
Thanks to the participation of Álava Ingenieros, the FANDANGO project was able to address the main challenges of the automotive components industry, such as the lack of technological solutions adapted to its particular needs. In this sense, the company contributed to the definition of technological solutions to guarantee the visibility of information throughout the supply chain, maximize the quality of the final product and optimize processes that do not provide direct value, such as maintenance.
RESULTS AND ACHIEVEMENTS
Surface inspection and dimensional control
To alleviate this problem, the project introduces advanced instrumentation solutions in the production line based on instrumentation and metrology systems for quality control, and the introduction of artificial vision systems with photonics for surface inspection and 3D dimensional control of the parts adapted to the specific needs of the line. These technologies allow progress in quality standards in manufacturing lines and the implementation of deep learning algorithms for the detection of multiple defects and continuous improvement, something new in this sector.
In addition, to achieve the three initial challenges, the FANDANGO project will employ the technology based on the Digital Twin, which consists of the construction of a virtual simulation of an asset, process or product, based on its physical characteristics and the data captures and parameters generated. In this way, through this virtual simulation or hybridization of models, it is possible to detect in advance the appearance of problems or failures in these assets, as well as to predict the results of the processes with greater precision than with pure simulation models.
The use of Digital Twin technology in industrial environments represents a real revolution when it comes to developing industrial maintenance plans and managing the predictive maintenance of the most critical assets, in addition to the possibility of anticipating in time possible incidents or events that may occur in the plant.
OUR EXPERIENCE
