Papers by Keyword: Assembly Line

Abstract: The advance of digitalization changes the requirements of processes in industrial production and assembly. For this reason, production and assembly must now be able to execute complex process steps. This is about quality and productivity expectations, as well as flexibility and reliability of production, lines and plants [1]. Today, data is generated by almost every system, machine and sensor, yet it is hardly used for process optimization. Manufacturing processes are usually organized as workshop production or chained production systems, in addition to standalone machines [2,3]. Most analytic projects focus on chained systems and serial production, unlike individual machines and specific workshop production. Depending on manufacturing IT, process data from serial production is stored in data bases, which are usually optimized for traceability. Standalone machines and machines within workshop production are scarcely connected to a common data base. The required process data is stored either on the module itself or inside a local data base [4]. The identification of dependencies between individual assembly processes, energy data and the quality of the finished product is necessary for an extended optimization. These optimizations can be process-specific, as well as environmental and resource related. Due to decentralized process data storages, an overall view of a dynamic order-oriented value chain is denied. Therefore, the potential of the machines is largely unused. Based on Data Mining, this advanced development can be counteracted by process monitoring and optimization. Therefore, this paper provides a solution for a virtual process data linkage of assembly stations. This enables the acquisition, processing, transformation and storage of unstructured raw data by special software and methods, which is also able to cope with chained production systems and standalone machines. For further analysis of interdependencies, a visualization is developed for advanced monitoring and optimization [5,6].

Abstract: Modern large-scale assembly lines need to deliver a highly varied and flexible output, while achieving 0 ppm scrap. This is becoming more and more demanding due to an increasing complexity of the products. Thus, it will be a major step in manufacturing processes to develop process monitoring strategies which increase productivity as well as flexibility and reliability of the entire assembly process. Therefore, it is necessary to advance the entire chained assembly line instead of only isolated processes and stations. For this reason, technological processes have to be assessed as a chain of upstream and downstream partial processes instead of being considered in isolation. [3] Moreover, data mining projects depend on the available data bases, while additional data sources may increase the derived knowledge. [2] These ideas are extendable by energy data measurements, besides process and quality data. Existing monitoring approaches to reduce scrap usually use dashboards linked with process and quality data. [5] Therefore, this paper presents a new methodology using data mining analysis of energy data for assembly presses as well as complete assembly lines for electromagnetic actuators. This novel holistic approach realized by a Quick Reaction System allows to increase efficiency, while decreasing energy and resource consumption for actuator manufacturing on large scale assembly lines. In particular, the data base consists of process and quality data, enriched by energy data measurements. This approach enables a comprehensive process characterization as well as monitoring of whole assembly lines by using data mining tools. Furthermore, this paper describes a quantitative evaluation of its data mining based event detection of critical process parameters.

Abstract: The purpose of this paper is to improve line productivity using line balancing technique and a reduction of work variation using an automated part feeder. This is due to the fact that the conventional assembly line manually feeds a part on to the production line by a worker. The feeding cycle is not constant and varies from time to time. Thus, the production rate is not constant and varied by the worker feeding speed. In addition, the assembly line itself does not fully balance. The operation time of each station is not well designed; as a result, all of the stations but the bottle-neck one experience an idle time. The balance efficiency is only at 40.33 percent which means that 59.67 percent of the total production time is balanced delay. Once the automated feeding machine which a buffer is designed and implemented. The cycle time can be set at 6 sec. and with the line balance technique the operator can be reduced from 11 to 9 persons. As a result, the productivity is substantially increasing around 138 percent and the new balance efficiency is 85.12 percent.

Abstract: This paper describes the design method of kitting systems for variant engine assembly, which contribute to performance of parts assembly flexibility and efficiency. The need for efficient material handling part delivery is higher especially in automotive industry due to extensive product customisation and the small area to keep all the necessary parts at the assembly line. The paper focuses on the suitability of design KS in the essence of reliability, safety and ergonomics of workers. Relatively, the design consider the flexibility of the kit process in engine assembly parts with regard to performance measurement resulting in overall efficiency and accuracy of production line. Associated with Lean approach, KS provide an essential outcome required that avert a non value adding activities to take place in assembly line. It is believed that the findings of this study will provide an optimum efficiency of part feeding process between variant parts model. In particular, KS is cost efficient when extensive sorting process, parts model misplaced and lack of space can be avoided.

Abstract: The paper compares the assembly process of milling machine using two systems: cell system and production line which was introduced after the changes in the machine assembly system of the company. Assembly in both systems takes place in the SKD (semi-knocked-down) system, which consists of assembly finished, large parts of the machine (higher completeness units) imported into the country of installation. The illustrated example presents advantages and disadvantages of assembly of milling machines in two systems: cell assembly and on the assembly line. In this example, the employees in each cells conducted assembly of machines divided into stages, which was dependent on the supply of items in the designated field by warehouse workers. Warehouse department receives a signal at what stage the assembly process is and whether the delivery of certain items is necessary. The assembly system was reorganized and replaced by the assembly line. This assembly, as previously cell assembly, is carried out in SKD system, which is a partially exploded into components. Previously assembly method took place in three stages. After the change to the assembly line this process takes 14 steps.

Abstract: This research objective is to improve the productivity of cookware assembly line by means of time and distance reductions. The motion study and line balancing techniques were applied to the entire assembly operations. A bottle neck was identified to where the operation with inadequate machine layout and workplace organization, including the unbalanced workloads. The new workplace layout and new working method for operators were designed and implemented as well as balancing the assembly line. Specifically, the conveyor speed and duration between the consecutive workpieces in the production line were adjusted to 0.10 m/s and 50 cm, respectively. The number of operators needed in the process can be reduced from 14 persons to 11 persons. The cycle time for assembling process is decreased from 12 to 5 second.

Abstract: Printed circuit board (PCB) assembly planning problem has been given lot of attention to efficiently manage the orders of different PCB products. However, little effort has been paid to describe its comprehensive model which can demonstrate all the planning problems collectively considering in the surface mount technology (SMT) lines. A mixed integer model for PCB assembly line which includes the integration of different levels of the planning problems and considered component allocation problem (line balancing), PCB model sequencing problem (mixed model sequencing problem), feeder arrangement problem and component placement sequencing problem on different SMT machines collectively. Current research is significant to solve different planning problems of the PCB assembly line simultaneously to get the overall global solution of the problem in future.

Abstract: The present paper is part of a larger study of the authors, which consists in the analysis of performances of several production systems. On a multiproduct assembly line supplied in Strike-Zone, are made researches on the influence of the method of production flow management, the method of launching in production and by varying the clients demand size on several performance indicators. The assembly line has mainly manual activities, divided in 5 workstations. The line produces two types of similar products. Using dynamic simulation (Arena software) that mimics the lines functioning mode, different experimental conditions are created, determined by the variation of the above mentioned parameters, following the evolution of the performance indicators: average work in process, cost per unit, systems reactivity to client demand and throughput. The obtained results were interpreted and structured, in a manner to help the process managers to take adequate decisions considering the wanted objectives.

Abstract: In Line Balancing principles, the total workload in the assembly process is divided as evenly as possible among the workstations, without violating the sequences and relations in the assembly operations. Line balancing is important in an assembly system as it balances the line and increases the efficiency, as well as the productivity of a system. A case study was conducted in the assembly line of an electrical accessories manufacturer in Malaysia. The cycle time for each station was recorded, and the standard cycle time was estimated. The productivity, as well as the efficiency of the current assembly line, were studied. In terms of the productivity, the performance of the current systems was 500 units/worker/day, while the expected productivity was 600 units/worker/day. An assembly line setting was proposed based on the Line Balancing Method; the productivity for the proposed line increased to 671 units/worker/day, or in rough additional increase around 34%.

Abstract: With the development of the LED bulb assembly line, the demand of the production line monitoring system is getting higher and higher. A real-time LED bulb assembly line monitoring system based on the OPC technology and Microsoft Visual Studio 2010 software is established. The real-time data of the LED bulb assembly line is provided to achieve the function which concludes alarming, scheduling, showing and so on. LED bulb assembly line monitoring system provides the strong safeguard for the smooth operation of production line.