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MATERIALS • PROCESSES • FINISHES


Using virtual builds, simulation and


validation via CAD, manufacturers can ensure that all the components fit together for each design release and can be accessed and manipulated during the build. Any issues with component compatibility, design or accessibility can be tackled at a much earlier stage and, crucially, before time and money have been invested in one-off component manufacture for the prototype. Using this methodology, the team


can develop operation sheets as they go, making the final assembly process easier and more intuitive. Fixturing and work-holding are also considered at an earlier stage, meaning that manufacturers have more time to specify and produce a bespoke system, if required. Tis is especially true when dealing with larger or more complex assemblies, which do not lend themselves to easy movement or manipulation. In effect, assembly process design – including process, flow, tooling and fixturing – is completed before the physical components are ready to be assembled. By adopting this holistic approach, it’s easier to identify and fix issues faster than would be achieved during final assembly, with programme time savings of over 25% often achievable. What’s more, the extra efficiency afforded by POP allows assembly technicians to identify cost reduction opportunities for components and processes through ‘practice runs’ for future assembly.


The benefits of POP can be achieved in any sector where precision and replicability are vital


Productiv has been developing and testing this method, and the results have been impressive. In one instance, the team was able to reduce the assembly time for the first prototype build of a complex transmission for an automotive manufacturer from their typical eight weeks, to just eight days. Te benefits of the POP approach can be applied in any sector for which precision and replicability are vital to


enable accurate testing and validation. In fact, any engineering business can achieve lower costs and a faster route to market. Productiv’s hope is that this will finally give prototypes the attention they deserve.


Alan Francis is head of operations at Productiv. www.productivgroup.com


SMART ENGINES COLLABORATION L


A CAD rendering of an automotive engine that Productiv worked on


54 www.engineerlive.com


ibertine FPE, the creator of Smart Engine technology for electric vehicles (EVs), has joined forces with Productiv to accelerate and de-risk commercialisation of a range of modular Smart Engines using Libertine’s intelliGEN platform. The collaboration will focus on


delivering electric vehicle and lab- based prototype power generator systems to showcase Libertine’s modular Smart Engine packaging concept, and demonstrating


the Smart Engine performance made possible by the firm’s linear e-machine and controls technologies. In addition, Libertine and


Productiv are planning to establish pilot manufacturing systems at Productiv’s facility at The Proving Factory in Coventry, UK to support Smart Engine client product developments with pre-production prototype systems including full vehicle demonstrations. l


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