Optimize the process and find new ways of data management.
May 18, 2021
Motores is the largest engine plant from Groupe Renault and also a reference for Renault-Nissan-Mitsubishi Alliance. With 55 years of activity, we have manufactured more than 32 million of engines. Nowadays, we produce 1 engine every 11 seconds.
In our plant of almost 300 m2 we have, 3 engine assembly lines, 22 machining lines and 8 aluminium cast presses.
The big and great human team working together make possible the success of the plant. Valladolid Engine Factory supplies engines to 22 factories distributed in the 4 continents and 78% of the production is exported to equip Renault, Nissan, Dacia, Samsung and Daimler brands.
How did you learn about the project? What aspects of the project attracted you to join it?
We’ve heard from the project because our French colleagues told us about the InterQ project and thanks to their unavailability we were able to step into it. There were 2 principal aspects that immediately attracted us. First, the extended expertise of the partners and the diversity of the knowledge. And second, the opportunity of learning as much as possible of our machines in order to optimize our process and find new ways of data management to achieve our goals.
How is work carried out at your production plants on a daily basis?
Our plant produces 6 engine types and manufactured 6 parts which make up the heart of the engine: cylinder block, cylinder head, crankshaft, camshaft, flywheel and conrod.
Engine manufacturing requires highly specialized facilities with means that combine high precision and high capacity to enable complex operations. The objective is clear, to manufacture engines that drastically reduce CO2 consumption and the cost of use. A mechanical performance that is based on technological excellence acquired in F1 and applied to series vehicles.
Why is Zero-Defect Manufacturing so important for your company?
The quality of our engines and customer satisfaction is the priority of MOTORES after security. Be able to detect defect before it happens is important to us. One of our actuals goals is to reduce the number of scraps or detect them efficiently before they reach the assembly line and the production rate is so high that it is impossible to properly control the part quality using standard metrology, that’s why zero-defect manufacturing could be a solution.
Which are the main problems faced currently?
MOTORES plant is benchmark concerning quality objectives in Renault group, but we’re very strict with ourselves and we are always looking forward to improving our KPIs. Due to the big number of pieces and engines manufactured per day (1 part every 11s) we would like to improve the life of our tools, avoiding the tool breakage to be able to reduce maintenance stops.
How do you expect InterQ will improve your production?
Improve process capability and product quality in machining operations obtaining real time data analyses to predict machine behaviour. This will allow us to improve our KPIs, while testing and implementing new sensors and actuators to make the machines talk (CBM). Further, once a production line is running, the reconfiguration for other product reference is difficult and the ramp up time should be reduced, a digital twin creation will be helpful managing this situation.