BIW Engineering Competence
Comprehensive capabilities across the entire BIW lifecycle – from simultaneous engineering to commissioning support
Our Engineering Philosophy
PLAN • DESIGN • MANAGE • VERIFY • VALIDATE • REALIZE
PLAN
DESIGN
MANAGE
VERIFY
VALIDATE
REALIZE
200+
Design Engineers
500+
Projects Completed
25+
Global OEM Partners
29+
Years Experience
Simultaneous Engineering
Parallel processing from product concept to market launch, significantly reducing development time and accelerating market entry.
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 to achieve required output as defined by OEMs 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 pre-production, production, and quality assurance fixtures.
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 and compliance 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 (Emplant, Quest)
OEM Standards & Add-ons
- GM KBTD & Validat
- Daimler Add-ons
- VW/Audi/SEAT/Skoda Standards
- Ford Standards
- Heidelberg Quality Manager
- Q-Checker
Documentation & Technical Analysis
Comprehensive documentation services ensuring foolproof planning, execution, verification, and validation.
Process Documentation
- Clamping plans
- Weld study & gun design
- Spot distribution analysis
- Cycle time sheets
- Process data sheets
- Pneumatic diagrams
Engineering Analysis
- Robot payload analysis
- Clamp validation & design calculations
- Ergonomic assessments
- Gun section drawings
- Cylinder & switch specifications
Technical Publications
- Maintenance manuals
- Technical brochures
- Risk analysis (DIN EN 1050)
- Simulation & OLP documentation
- Technical presentations
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
- Data visualization
- 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
Advanced Simulation Services
Full-service simulation capabilities validating designs before physical implementation, reducing costs and time-to-market.
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
Process Validation
Comprehensive validation ensuring process intent and operational feasibility.
- Tooling validation
- 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 scenarios
- 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
- Budget management
- Risk management
- Stakeholder communication
Execution Management
On-ground management ensuring seamless implementation and commissioning.
- Site management
- Vendor coordination
- Quality assurance
- Equipment management
- Installation supervision
