Design Method of Kitting System in Flexible Assembly Line Based Manufacturing for Mass Customisation Adaptation

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.

• Periodical: Advanced Materials Research (Volume 1134)
• Pages: 243-248
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.1134.243
• Online since: December 2015
• Authors: Wan Ahmad Najmuddin Wan Saidin*, Mohd Azam Musa, Nazrul Idzham Kasim, M.H. Norhidayah, Siti Solehah Ramli
• Keywords: Assembly Line, Design for Assembly, Kitting System, Mass Customisation

References

[1] S.Y. Hua, and D.J. Johnson, Research issues on factors influencing the choice of kitting versuslinestocking, International Journal of Production Research, 2010; 48(3), pp.779-800.

DOI: 10.1080/00207540802456802

[2] G. Chryssolouris, N. Papakostas, N., D. Mavrikios, A Perspective on Manufacturing Strategy: Produce more with Less, CIRP Journal Manufacturing Science and Technology, 2008; 1(1), p.45–52.

DOI: 10.1016/j.cirpj.2008.06.008

[3] G. Chryssolouris, Manufacturing Systems: Theory and Practice, 2nd ed. Springer-Verlag, New York, (2006).

[4] M.A. Corakci, An evaluation of kitting systems inlean production, Master thesis, 2008; University Of Boras, Boras.

[5] Y.A. Bozer, and L.F. McGinnis, Kitting versus line stocking: a conceptual framework and a descriptivemodel, International Journal of Production Economics, 1992; 28(1), pp.1-19.

DOI: 10.1016/0925-5273(92)90109-k

[6] L.L. Kosteand M.K. Malhotra. A theoretical framework for analyzing the dimensions of manufacturingflexibility, Journal of Operations Management, 1999; 18(1), pp.75-93.

[7] L. Medbo. Assembly work execution and materials kit functionality in parallel flow assembly systems, International Journal of Industrial Ergonomics, 2003; 31, pp.263-281.

DOI: 10.1016/s0169-8141(02)00220-2

[8] A. Caputo and P.M. Pelagagge. A methodology for selecting assembly systems feedingpolicy, Industrial Management & Data Systems, 2011; 111(1), pp.84-112.

DOI: 10.1108/02635571111099749

[9] C.J. Sellers and S.Y. Nof. Part kitting in robotic facilities, Material Flow, 1986; 3(1-3), pp.163-174.

[10] M.I. Johansson. Kitting systems for small size parts in manual assembly systems, in Pridham, M. and O'Brien, C. (Eds), Production Research: Approaching the 21st Century, Taylor & Francis, London, 1991; pp.225-230.

[11] L. Medbo. Materials supply and product descriptions for assembly systems – design andoperation, Dissertation, 1999, Chalmers University of Technology, Go¨teborg.

[12] F.Y. Ding and B. Puvitharan. Kitting in just-in-time production, Production &InventoryManagement Journal, 1990; 31(4), pp.25-28.

[13] F.Y. Ding. Kitting in JIT production: a kitting project at a tractor plant, IndustrialEngineering, 1992; 24(9), pp.42-43.

[14] H. S. Kilic &M. B. Durmusoglu. Design of kitting system in lean-based assembly lines. Assembly Automation, 2012; 32(3), pp.226-234.

DOI: 10.1108/01445151211244357

[15] D. Alford, P. Sackettand G. Nelder. Mass customisation – an automotive perspective, International Journal of Production Economics, 2000; 66(1), pp.99-110.

DOI: 10.1016/s0925-5273(99)00093-6

[16] R. Hanson, L. Medbo andP. Medbo. Assembly station design: A quantitative comparison of the effects of kitting and continuous supply. Journal of Manufacturing Technology Management, 2012; 23(3), pp.315-327.

DOI: 10.1108/17410381211217399

[17] C. Wänström andL. Medbo. The impact of materials feeding design on assembly process performance, Journal of Manufacturing Technology Management, 2009; 20(1), pp.30-51.

DOI: 10.1108/17410380910925398

[18] W.P. Neumann and L. Medbo. Ergonomic and technical aspects in the redesign of material supply systems: Big Boxes vs Narrow Bins, International Journal of Industrial Ergonomics, 2010; 40(5), pp.541-548.

DOI: 10.1016/j.ergon.2010.06.004

[19] C. Finnsgård, C. Wänström,L. Medbo andW.P. Neumann. Impact of materials exposure on assembly workstation performance. International Journal of Production Research, 2011; 49(24), 7253-7274.

DOI: 10.1080/00207543.2010.503202

[20] R. Hanson, Effects of using minomi in in-plant materials supply, Journal of Manufacturing Technology Management, 2011; 22(1), pp.90-106.

DOI: 10.1108/17410381111099824