BIW Engineering Competence - Design, Simulation & Controls | Advance Mechanical Services

BIW Engineering Competence

Comprehensive capabilities across the entire BIW lifecycle – from simultaneous engineering to commissioning support

200+ Design Engineers

1000+ Projects Completed

25+ Global Partners

29+ Years Experience

Our Engineering Process

A systematic approach ensuring excellence at every stage

PLAN

DESIGN

MANAGE

VERIFY

VALIDATE

REALIZE

Simultaneous Engineering

Parallel processing from product concept to market launch, significantly reducing development time

Project-Based Interface Coordination

We specialize in coordinating all product and production processes simultaneously, ensuring seamless integration across departments and stakeholders.

Cross-functional team collaboration
Real-time communication protocols
Milestone synchronization
Risk mitigation strategies

Development Time Optimization

Our SE approach achieves maximum benefits during new product development, particularly valuable given ever-shorter product life cycles.

Reduced time-to-market by 30-40%
Parallel workflow execution
Early issue identification
Continuous feedback loops

On-Site & In-House Collaboration

We work flexibly on SE projects both in-house and in cooperation with customers on-site, adapting to project requirements.

Customer facility integration
Dedicated project teams
Knowledge transfer programs
Agile methodology implementation

Process Engineering Excellence

Developing optimal production processes through scientific analysis and continuous improvement

Process Finalization

Complete process engineering from initial concept through production-ready specifications.

Process flow definition
Station sequencing
Operation standardization
Quality checkpoints integration
Production validation

Cycle Time Optimization

Scientific approach to reduce cycle times while maintaining quality and safety standards.

Time study analysis
Bottleneck elimination
Motion economy principles
Automation opportunities
Continuous monitoring

Line Balancing

Achieving optimal production output through strategic workload distribution across stations.

Workload analysis
Resource allocation
Takt time alignment
Efficiency maximization
Flexibility planning

Comprehensive Design Capabilities

Full spectrum of BIW tooling design services covering all production phases

Pre-Production Tooling

Prototype and pilot phase tooling designed for validation and early production trials.

Prototype fixtures
Pilot line tools
Validation equipment
Trial assembly jigs

Production Tooling

High-volume manufacturing tools engineered for durability, precision, and efficiency.

Geometry fixtures
Respot fixtures
Assembly tools
Material handling equipment
Robotic end effectors

Checking Fixture Tooling

Precision measurement and quality validation systems for all BIW components.

Stamping gauges
Ring gauges
PCF (Blue Buck)
SPC tooling
Exterior bucks

Software & Technology Expertise

Industry-leading tools and OEM-specific standards ensuring compatibility across all projects

Design Software

CATIA V5
UG NX
Pro-E/CREO
SolidWorks
Inventor
FIDES

Layout Tools

Factory CAD
MicroStation
AutoCAD
Plant Design
MicroStation FAPLIS

Simulation & OLP

Process Simulate
DELMIA
Robcad
iGrip Ergo
Discrete Event Simulation

OEM Standards

GM KBTD & Validat
Daimler Add-ons
VW/Audi/SEAT/Skoda
Ford Standards
Heidelberg Quality Manager
Q-Checker

Documentation & Technical Analysis

Comprehensive documentation services ensuring excellence in planning, execution, and validation

Process Documentation

Clamping plans with detailed specifications
Weld study & gun design documentation
Spot distribution analysis reports
Cycle time sheets and optimization data
Process data sheets for all operations
Pneumatic diagrams and schematics

Engineering Analysis

Robot payload analysis and optimization
Clamp validation & design calculations
Ergonomic assessments for operator safety
Gun section drawings and specifications
Cylinder & switch specifications
Structural integrity analysis

Technical Publications

Comprehensive maintenance manuals
Technical brochures and guides
Risk analysis (DIN EN 1050)
Simulation & OLP documentation
Technical presentations and reports
Training materials and procedures

Controls Engineering & Automation

Complete electrical and controls engineering capabilities for modern automated BIW lines

PLC Engineering

Comprehensive PLC programming and architecture design for all major platforms.

PLC architecture design (line & cell level)
Power distribution architecture
Offline PLC programming
Siemens, Allen-Bradley, Mitsubishi
Virtual commissioning

HMI Development

User-friendly human-machine interfaces designed for operational efficiency.

HMI offline programming
Screen design & navigation
Alarm management systems
Data visualization dashboards
Multi-language support

Robot Programming

Expert robotic programming with VASS V5/V6 certification for Volkswagen Group standards.

ABB robot programming
KUKA robot programming
FANUC robot programming
VW/Audi/SEAT/Skoda certified
System integration support

Simulation Services

Full-service simulation capabilities validating designs before physical implementation

Robotic Simulation

Complete validation of robotic applications across all welding and handling processes.

Spot welding simulation
Arc welding simulation
Material handling validation
Cycle time calculation with RCS
Collision detection and prevention

Process Validation

Comprehensive validation ensuring process intent and operational feasibility.

Tooling validation studies
Weld gun validation
System layout verification
Robot motion optimization
Accessibility studies

Discrete Event Simulation

System-level analysis for throughput optimization and capacity planning.

Throughput analysis
Bottleneck identification
Buffer capacity optimization
What-if scenario testing
Manpower planning

Full-Service Project Management

End-to-end project management ensuring on-time, on-budget delivery with quality excellence

Engineering Program Management

Strategic oversight of complex multi-disciplinary engineering programs.

Project planning & scheduling
Resource allocation and optimization
Budget management and control
Risk management strategies
Stakeholder communication

Execution Management

On-ground management ensuring seamless implementation and commissioning.

Site management and coordination
Vendor coordination and oversight
Quality assurance programs
Equipment management
Installation supervision

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