High Performance Assembly Facility

This state-of-the-art production facility provides a near clean room production environment in which each and every process is carried out according to strict quality principles and within a comprehensive ‘no faults forward’ culture.

 

The facility builds upon the established reputation of the Ricardo Performance Products group which is already well-known for the production of the advanced Ricardo-designed transmissions for the iconic Ford GT and the Bugatti Veyron supercar, as well as numerous driveline systems and components for the highest levels of competitive motorsport.

Facility overview

The facility incorporates best practice lean manufacturing principles and is a showcase for Ricardo know-how. assembly line plan

  • 13 station assembly process
  • 10 station main assembly line plus;
  • Break-in pass-off (BIPO) rig/de-rig
  • BIPO cell
  • 88-point pre-delivery inspection (PDI)
  • 6 station cylinder head sub-assembly line
  • 45 minute Takt time
  • Single Piece Flow (1 engine per station)
  • Minimal in process stock
  • Line-side delivery of components into flow racks
  • 2,000 engines per year (single shift)

 

Main line assembly processRicardo knowledge

  • Human-machine interface (HMI) at each station
  • Contains work standard
  • Automatic indication of  tool selection
  • Tracks build and cycle time status
  • DC tools at each station
  • Sets fastening programmes automatically
  • Measures rundown rotations, angle and torque
  • All rundown results saved to the database agains engine number - full birth history
  • Operator must accept each operation by pressing “step complete” button
  • Pneumatic interlock will only release if all work steps completed
  • Light curtain control for bearing selection
  • 2D liquid gasket plotter interlocked to main line

 

BIPO cell

  • Motoring dyno
  • Auto dock/undock
  •  Auto oil/coolant fill
  • Pre-heating of fluids
  • Safety systems:
  • FM200 fire suppression system
  • Smoke and flame detectors
  • Explosion protection
Victoria Assembly line quality

Quality systems

  • 3 focused quality gates (3, 7 & 10)
  • Integrated quality systems into every station
  • Poke-yoke error-proofing
  • DC tools
  • Traceability through serialisation and lot control
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Key benefits 

Ricardo is exceptionally well placed to provide the very latest in new product engineering skills and has long been able to take-on the toughest challenges of performance product design and development. By extending this service to the simultaneous engineering of state-of-the-art assembly facilities and the development, qualification and management of the supply chain, Ricardo can add significant value in a highly complementary manner to its customers’ premium product aspirations.