Tjahjono, ball, ladbrook, and kay 2009 applied simulation and the taguchi method to derive a set of principles that can be used by engineers and practitioners to design manual assembly lines. Johansson 1991 describe and analyses three different principles of feeding materials to an assembly station, namely continuously, batch supply, and kitting. In the case of manual assembly, an operator sometimes need more time to complete the task causing starvation at the next workstation, or conversely, is quicker. Pdf many variables and constraints must be taken into account when designing a manufacturing facility such as an assembly line, which often depends on.
To offer lean design and assembly principles with a focus on monozukuri, meaning sustainable, environmentally friendly factories and products with simultaneously integrated product and process designs. As system integrators, we look at every manufacturing problem as an. Manufacturing system design based on axiomatic design. Master of science thesis in the international masters programme automotive engineering. In this paper we develop an optimal and a heuristic algorithm for the problem of designing a flexible assembly line when several equipment alternatives are available. By following these principles of flexible assembly line design, manufacturers can pursue lean manufacturing in their current operation while also.
So, these workstations were placed with 180o opposite orientation to that of current orientation of the assembly line. Dfa is the method of design of the product for ease of assembly. Seek guidance on when to automate and when to retain manual processes. The information needs to be presented in a clear and unambiguous manner so as to avoid confusion by the user. Chapter 11 drive lines, differentials, drive axles, and. A methodology is proposed that helps to improve the productivity of any production process.
Pdf on apr 8, 2015, ranjith raja and others published assembly line design and. Bus assembly, assembly line design, assembly line balancing. Fully supported by case studies, this book links the technologies of manual, dedicated, and flexible assembly to the established rules of design for assembly. One of these workstations is placed at the beginning of each line as it was required at start of the line. Having analyzed the system, the students use lean principles such as 5s, visual control, standard. Integrating ergonomics and lean manufacturing principles. A primary strategy in dfm involves minimizing the number of parts in a product. Students will illustrate in their own words, henry fords 3 principles of assembly. Methodology and applications manufacturing engineering and materials processing chow, wemin on. Assembly line design principles using six sigma and simulation. Design the assembly using base parts to which other components are added. Layout is adjusted through ushaped line to bring down the distances between the removal point and the assembly line of doors. It includes key datain this case, the amount of time spent at both the mandated tasks i.
Unfortunately, like many other design processes, it can be timeconsuming and repetitive. Efficient assembly line design is a problem of considerable industrial importance. An application from cooler manufacturing industry 35 the design matrix at this level is an uncoupled. Send turning power from the transmission to the rear axle assembly. Bus assembly, assembly line design, assembly line balancing, applications of concepts instantly after learning from books has been an project steps and applied methodology to carry out this study, and explains the course.
Pdf assembly line design and balancing researchgate. Related works in recent years, many studies have dealt with different facets of production line design to reach several objectives through several methods. Plant layout begins with the design of the factory building and. Moreover, the door trim, glass and hard ware can be.
Assembly line design methodology and applications pdf keywords. June 8, 2018 in argonaut by implementing these five principles of flexible assembly line design, manufacturers can pursue lean manufacturing in their current operation while also building in capability to maintain or. Flex and allow upanddown movement of the rear axle assembly. Provide a sliding action to adjust for changes in drive line. Thus, in figure 4, there are two yellows for every green and two yellows for every red. Based on using the building block profiles system in design process, it is possible to create for example workstations, as well as entire production lines, that can be quickly adapted to varying work content and avoiding waste in line with lean principles, e. The heart of any design for manufacturing system is a group of design principles or guidelines that are. Pdf assembly line balancing by using axiomatic design. The in itial assembly line design focuses on creating. Pdf assembly line optimization using lean principles. Assembly line design using a hybrid approach of lean.
The process allows easier access to the interior assembly of the car. With mixed model assembly, figure 4, multiple models are interspersed on the same assembly line. An assembly line is a manufacturing process in which parts are added to a product in a sequential manner using optimally planned logistics to create a finished product in the fastest possible way. The idea is to use simulation models as a basis for experimentation of parameters that are critical to the productivity of the lines. The assembly should be designed so that components are added from one direction, usually vertically. Demanded operation distribution to stations is made by manual manipulation on. Simulation improvements lean principles typical student actions organize activity 5s, visual control, standard work clean up worksite, organize inventory, standardize sequence of ordering, assembly, and paperwork balance workload between facilities this requires.
Assembly line design principles using six sigma and. Given the production requirements, product characteristics and assembly tasks, the model defines the assembly process for hybrid assembly lines with both manual workers and automated assembly. The results show that by changing over to the single stage assembly line configuration the operator productivity is doubled when compared to the existing assembly method. Dfma advantages quantitative method to assess design communication tool with other engineering disciplines and other departments sales, etc. Methodology and applications manufacturing engineering and materials processing. The problem of optimal design of the assembly lines is considered. Design of information displays, pt mercer university. Part features such as chamfers and tapers should be designed on mating parts. In addition to this, assembly line design is often complex owing to the number of multiple components involved.
Improvement in material feeding system through introducing. Crew size sum of manual cycle time takt time if manual cycle time 1,293 seconds and a takt time 345 sec crew size 1,293 personseconds 345 seconds crew size 3. Csia 5 principles of flexible assembly line design. These are presented in a number of sections, which include. Various definitions of problems have been established together with different approaches as to the way they are solved. This paper explores the applicability of six sigma and simulation techniques to derive a set of principles that can be used by manufacturing engineers to design assembly lines. The design process is inherently a complex task affected by. Assembly line design principles using six sigma and simulation conference paper pdf available in proceedings winter simulation conference january 2010 with 712 reads how we measure reads. Students will construct a system of improved efficiency for a task in their own lives. Job design is how organizations define and structure jobs. Assembly lines design and balancing are one of the challenging aspects of automotive production lines.
These are shown in fig 2, and categorized with regard to. Assembly line balancing by using axiomatic design principles. Design of flexible assembly line to minimize equipment. Crew size calculation for an assembly line doing one piece flow paced to takt time is. Assembly line design and balancing designing and balancing the audi b9 mirror assembly line at smr automotive mirrors technology, mosonszolnok, hungary master of science thesis in the masters programme production engineering ranjith raja department of product and production development division of production systems. However, in the automotive industry, most companies still use simple tools and methods for the solution of these problems. The ratio of each model to total output is consistent with customer demand.
Materials feeding mainly concern what principle to use for feeding the materials to a workstation or an assembly line. The aim was to provide an effective, efficient assembly line design tool that meets the lean principles and ergonomic requirements of safe assembly work. Pdf assembly line design principles using six sigma and. By following these principles of flexible assembly line design, manufacturers can pursue lean manufacturing in their current operation while also building capabilities to maintain or add lean improvements in the future. Design for manufacturing dfm refers to design activity that is based on minimizing the cost of production andor time to market for a product, while maintaining an appropriate level of quality.
Greater role for other groups while still in the engineering phase such as manufacturing since almost 75% of the product cost is determined in the engineering phase, it gives a tool to attack. Introduction several industries utilize lean manufacturing to increase the value of their products and reduce all form of waste. Integrating assembly lines based on lean line design. In one plant, it is almost parallel to the final inspection line. Pdf assembly line design principles using six sigma and simulation. As we will see, properly designed jobs can have a positive impact on the motivation, performance, and job satisfaction of those who perform them. The design problem addresses the questions of selecting the equipment and assigning tasks to workstations, when precedence constraints exist among tasks. This is an excerpt from an article in automation world by mark sobkow, vice president of manufacturing solutions. Pdf on apr 8, ranjith raja and others published assembly line design and balancing find, read and cite. Principles for systematic layout planning slp were published by richard. Indeed, our objective is to find a truthful method of production line design to reach many objectives. The current project addresses the productivity improvement of a manual assembly line by making use of operations analysis in the framework of lean production. The assembly line and simulation tool used 3 methodology the overall aim of this project is to provide a set of principles that can be used to assist manufacturing engineers in the design of the assembly lines in order to maximize their productivity. Students will contrast the automobile production process before and after the advent of the assembly line.
The objective is to minimize total equipment costs, given a predetermined. An assembly line is a manufacturing process in which interchangeable parts are added to a product in a sequential manner to create an end product. Assembly line design methodologies have been extensively researched during the past decades. But, the workstation for other component which was required after two operations was a problem. Optimization of the partsystem assembly dfa is a tool used to assist the design teams in the design of products that will transition to productions at a minimum cost, focusing on the number of parts, handling and ease of assembly.
Overview of design for manufacturing and assembly dfma. Assembly line design methodology and applications pdf. Human factors design guidelines for multifunction displays. Multicriteria assembly line design under demand uncertainty. Job design job design is an important method managers can use to enhance employee performance.
Design for assembly dfa has become an increasingly important concept in designing products for todays markets. Integrating assembly lines based on lean line design concept. Plant layout means the disposition of the various facilities equipments, material, manpower, etc. It is a floworiented production system where the productive units performing the operations, referred to as stations, are aligned in a serial manner. Many variables and constraints must be taken into account when designing a manufacturing facility such as an assembly line, which often depends on. Restructuring and balancing of the bus pre assembly line at man nutzfahrzeuge ag ankara factory. This article throws light upon the five main types of layout.
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