Quality assurance on BMW convertibles

Measuring Systems: TRITOP

Keywords: Process optimization in production line, Quality assurance in production, Validation of fitting dimensions, Calibration stability of assembly jigs, MCS, PCS

Mobile optical 3D coordinate measuring technology is used for quality assurance on the production line in the BMW Regensburg plant. For the assembly of roof modules for convertibles, optical measuring equipment is used in process planning for the machine capability study (MCS) even before the start of serial production.

On the assembly line the photogrammetric system then enables flexible inspection to be carried out during manufacture. Thus trends and deviations in production can be detected at an early stage. As result of using optical metrology rework time is reduced and production costs are cut down significantly. Also Quality
Management can be specifically improved by means of process capability studies.

In the BMW Regensburg plant, all the necessary production steps for automobile manufacture, from the press and body shops to final assembly, are located on one site. In assembly, as the last section at the heart of the manufacturing process, finished BMWs are produced from approximately 20,000 components in about 100 working steps. Here, in a unique range of variants, the BMW 1-Series (5-door), the sedan, the coupe and the convertible from the BMW 3-Series as well as the corresponding M3 models, and also the BMW Z4 Roadster are produced in a mixed stream on a variant-neutral main conveyor. This type of individualized automobile production requires classical manufacturing care and the most up-to-date logistical control in assembly. The individual parts not only have to be supplied "just in time" but also "just in sequence", in other words in the order corresponding to the vehicles on the assembly line. In the case of the 3-Series convertible and the Z4 Roadster, roof module assembly is a particularly sensitive task. It places highdemands on the operatives, the process and the auxiliary equipment used. To secure this process the mobile optical TRITOP CMM system is used to monitor the distortion-free installation of the convertible hardtop modules, the quality of the seals and uniform gaps.

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