V436 Machining: EV Industrialization
Achieved 35 Million SEK in total cost savings and eliminated the need for 2 additional CNC machines (20M SEK CAPEX avoidance) through rigorous process optimization.
Project_Scope
Leading the end-to-end industrialization of Volvo's first in-house CNC machining line for EV battery enclosures in Olofström. This involved transitioning from external sourcing to high-volume in-house production while maintaining strict quality and environmental standards.
Core_Responsibilities
System Mapping & PLM
Developed the comprehensive Lead Time Map, Value Stream Maps, and detailed Process Flow charts for the two main production lines.
Developed the complete simulation model for the line using Siemens Plant Simulate and Facts Analyzer to verify efficiency and identify bottlenecks.
Successfully implemented MBOM and EBOM structures within Teamcenter.
Product Optimization
Collaborated with R&D and suppliers (Modig/Bromi) to optimize CNC components for EV battery trays.
Fine-tuned machining programs and G-codes to perfect machining sequences.
Engineered fixtures and handling trolleys to meet strict manufacturing standards.
Compliance & Quality
Led team in developing comprehensive PFMEA and the project Control Plan.
Developed environmental checklists and managed complex waste flows (Al-scrap, fluids) with Stena and Hydro.
Supply Chain & PM
Prepared RFQs and handled supplier assessments for machine, tooling, and chemical domains.
Conducted detailed safety compliance checks and led FAT/SAT alongside global suppliers.
Digital Integration
Engineered custom Power Apps tools to track process parameter changes.
Developed Power BI dashboards for real-time visibility into production quality and operational metrics.
Impact Analysis Log
| Metric | Baseline | Optimized |
|---|---|---|
| Total Financial Impact | Baseline Budget | 35M+ SEK Saved |
| Machining Optimization | Initial Program | 25M SEK Saving |
| Design Improvements | Standard Geometry | 10M SEK (DFM) |
| CAPEX Requirement | N+2 CNC Units | Optimized (Saved 20M) |
| Manual Data Entry | 100% Manual | 80% Reduction |
| Process Lead Time | Original Forecast | 15% Reduction |
Technical_Q&A
SYSTEM_SPEC
Manage project lifecycle from RFQ to steady-state production
Optimize CNC G-codes for mass production efficiency
Achieve EU Machinery and Battery Regulation compliance
Reduce process lead times via Siemens Plant Simulation
Implement IoT monitoring for predictive maintenance
Minimize environmental impact of machining by-products