When positioning add-on parts in the production of the Vectron locomotive, Siemens has been relying on laser projection systems from EXTEND3D – Part of Atlas Copco Group at the Munich-Allach plant since 2013. IPG Mobile not only replaced the positioning templates made from aluminum previously used, but also offers enormous advantages in terms of time and costs. Therefore, Siemens is planning to purchase new systems for further applications.
Challenge
In the production of Vectron locomotives at Siemens’ Munich-Allach plant, positioning add-on parts was traditionally done using large aluminum positioning templates. While effective to some degree, this approach presented several limitations. The templates were bulky, required considerable storage space, and needed to be manually lifted and aligned on the base frame. Regular maintenance and checks added to the workload. Most critically, when customer-specific modifications were introduced, new templates had to be custom-designed and manufactured externally—a process that could take two to three weeks. This lag often forced workers to improvise, using manual scribing methods that were both time-consuming and prone to error. Additionally, the manual inspection process meant that welded-on parts could sometimes be overlooked, posing a risk to overall build quality.
Solution
Laser from the IPG Mobile projecting on a metal surface
Key features included:
- Integration with CAD for precise projections.
- Adaptive projection to account for surface defects.
- A user-friendly interface requiring minimal training.
Impact & Key results
- Streamlined Production Process: Since implementing IPG Mobile, Siemens has saved time, reduced storage and maintenance requirements, and eliminated delays linked to design changes. What once took weeks can now be accomplished in just a few hours.
- Enhanced Quality Insurance: The laser projections allow workers to both position and verify multiple welded-on parts with high accuracy. This has enhanced both productivity and consistency.
- Future Improvements: Encouraged by the success of the system, Siemens plans to expand its use to additional applications at the Munich-Allach facility, continuing to replace traditional methods with more flexible, efficient laser-based solutions.
“The elimination of template handling is a major advantage for us. The ease of use of the system (IPG Mobile) allows our workers to work with it without any problems.”
Sahap-Tunc Sarpdag Siemens' Production Equipment Design Department
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