The assembly concept has to be developed before the logistics are planned. In many projects, the OEM or their system supplier involves SAS in product planning right from the start so that it is possible to influence system design even at this early stage.
Detailed product plans (design plans, parts lists, descriptions of individual parts, etc.) result from this collaboration which are used to produce exploded drawings and, above all, the assembly flow chart which shows the sequence in which the individual parts are assembled. The task of assembly planning is to divide up individual assembly steps successively in the correct sequence across the assembly cycles.
In large series production, the OEM's large series assembly cycle for volume products is generally between 1 to 4 minutes per vehicle. Cockpit assembly must of course also orient itself towards customer cycles. Each cycle is now filled with components to be fitted in the order shown in the assembly flow chart until the total expenditure time is as close as possible to 100% of the available cycle time.
The precise length of the act of assembly depends on a number of factors. These include the length of the assembly line (due to hall restrictions or existing systems), the speed at which the assembly line runs and the size of the workpiece carrier.
Final tasks without material take place in the line at the end of assembly. The electronic value creation is verified at the eCheck. The cockpit cables are connected to electrical test devices via a diagnosis interface. Connections and fitted variants are checked in this way. The final visual check (end-of-line check) is done to guarantee flawless delivery as regards the visible parts. Moveable parts are also tested for functionality.
A wide variety of assembly-related requirements which are fulfilled with various assembly concepts result from the product-specific and technical circumstances at the respective location. Our main requirements of the assembly process are constantly flawless quality, traceability and secured availability with short throughput and timings. With this, we guarantee smooth processes and first-class products.
Highly complex and innovatively produced
Function, comfort, ergonomics and safety – today's cockpit modules have to be able to fulfil all these standards. They are regarded as the most complex module in a modern motor vehicle.
SAS is the market leader in the manufacture of automotive modules. We offer various innovative customer solutions which are implemented conveniently, safely and individually. We cover all process steps in the process. From assembly, delivery and installation of the modules to recycling. Innovative technologies and the highest quality and safety standards are a constant focus throughout the entire process chain.
Several components – perfectly combined
Depending on the vehicle type, a modern cockpit comprises the vehicle crossmember, the steering column, the heating, ventilation and air conditioning unit, the cable wire harness, the ventilation channel, the front passenger airbag, the glove compartment, the combined instruments, the navigation and entertainment system, several switches and trim strips as well as the dashboard, which generally contains the centre console and the ventilation.
During production, a cockpit module is assembled on a separate cockpit module assembly line within a certain lead time, generally 100 – 120 minutes. After this, it is supplied just-in-sequence to the automotive manufacturer's assembly line.
Assistance and infotainment systems make up a large part of what customers find especially attractive and influence buying decisions. Today, modern cockpits have to act as an interface between humans and the vehicle and also guarantee maximum usability and support with information processing.
The technologies are either a part of or at least connected to the cockpits of modern vehicles. To the same extent as the production and final assembly of the car as an end product, the production of these cockpits is therefore strongly affected by the customer-specific design of a mass product.
Today, numerous model variants and equipment lines are derived from car models. These variants have a direct or indirect effect on the functions and the design of vehicle cockpits. Because of this, each variant has to be produced in accordance with customer wishes and within a minimum throughput time. Just about every vehicle that leaves an automotive plant today is unique due to the exponentially increasing number of options which can be combined.
Functional, comfortable and sustainable
We innovatively combine the materials provided by the OEM with new functions and technologies which offer convenience and functionality. We pay special attention to lightweight construction and sustainability. The design of our centre consoles completely fulfils both these points and therefore offers new visual stimuli.