Pdf assembly line design principles using six sigma and simulation. One of these workstations is placed at the beginning of each line as it was required at start of the line. Plant layout begins with the design of the factory building and. Having analyzed the system, the students use lean principles such as 5s, visual control, standard. The information needs to be presented in a clear and unambiguous manner so as to avoid confusion by the user. The assembly should be designed so that components are added from one direction, usually vertically. The in itial assembly line design focuses on creating. Integrating assembly lines based on lean line design. 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. Principles for systematic layout planning slp were published by richard. In one plant, it is almost parallel to the final inspection line.
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. Provide a sliding action to adjust for changes in drive line. Materials feeding mainly concern what principle to use for feeding the materials to a workstation or an assembly line. Chapter 11 drive lines, differentials, drive axles, and. Send turning power from the transmission to the rear axle assembly. Here are five principles, applicable across every type of manufacturing, where flexibility can be added to an existing assembly line to eliminate waste and build quality into the system. Pdf assembly line optimization using lean principles. Layout is adjusted through ushaped line to bring down the distances between the removal point and the assembly line of doors. 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. Assembly lines design and balancing are one of the challenging aspects of automotive production lines. Assembly line design using a hybrid approach of lean.
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. Dfma advantages quantitative method to assess design communication tool with other engineering disciplines and other departments sales, etc. Flex and allow upanddown movement of the rear axle assembly. 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. Moreover, the door trim, glass and hard ware can be. Methodology and applications manufacturing engineering and materials processing. Csia 5 principles of flexible assembly line design.
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. 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. Demanded operation distribution to stations is made by manual manipulation on. Many variables and constraints must be taken into account when designing a manufacturing facility such as an assembly line, which often depends on. The idea is to use simulation models as a basis for experimentation of parameters that are critical to the productivity of the lines. Thus, in figure 4, there are two yellows for every green and two yellows for every red. Johansson 1991 describe and analyses three different principles of feeding materials to an assembly station, namely continuously, batch supply, and kitting. As we will see, properly designed jobs can have a positive impact on the motivation, performance, and job satisfaction of those who perform them. Improvement in material feeding system through introducing. It is a floworiented production system where the productive units performing the operations, referred to as stations, are aligned in a serial manner. Assembly line design methodologies have been extensively researched during the past decades.
Job design job design is an important method managers can use to enhance employee performance. 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. The problem of optimal design of the assembly lines is considered. Part features such as chamfers and tapers should be designed on mating parts. Pdf many variables and constraints must be taken into account when designing a manufacturing facility such as an assembly line, which often depends on. Indeed, our objective is to find a truthful method of production line design to reach many objectives. 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. Job design is how organizations define and structure jobs. Manufacturing system design based on axiomatic design. The aim was to provide an effective, efficient assembly line design tool that meets the lean principles and ergonomic requirements of safe assembly work.
This article throws light upon the five main types of layout. So, these workstations were placed with 180o opposite orientation to that of current orientation of the assembly line. An application from cooler manufacturing industry 35 the design matrix at this level is an uncoupled. Assembly line design methodology and applications pdf. These are presented in a number of sections, which include. 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. However, in the automotive industry, most companies still use simple tools and methods for the solution of these problems. Pdf assembly line design principles using six sigma and. Integrating ergonomics and lean manufacturing principles. Pdf on apr 8, ranjith raja and others published assembly line design and balancing find, read and cite. Design the assembly using base parts to which other components are added.
Integrating assembly lines based on lean line design concept. Pdf on apr 8, 2015, ranjith raja and others published assembly line design and. 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. 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. Crew size calculation for an assembly line doing one piece flow paced to takt time is. It includes key datain this case, the amount of time spent at both the mandated tasks i. 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. Overview of design for manufacturing and assembly dfma. 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. Human factors design guidelines for multifunction displays. 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. Pdf assembly line design and balancing researchgate.
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. Unfortunately, like many other design processes, it can be timeconsuming and repetitive. The design process is inherently a complex task affected by. Restructuring and balancing of the bus pre assembly line at man nutzfahrzeuge ag ankara factory. 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. The current project addresses the productivity improvement of a manual assembly line by making use of operations analysis in the framework of lean production. As system integrators, we look at every manufacturing problem as an. Related works in recent years, many studies have dealt with different facets of production line design to reach several objectives through several methods. Seek guidance on when to automate and when to retain manual processes. 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. Students will construct a system of improved efficiency for a task in their own lives. Assembly line design methodology and applications pdf keywords.
Students will contrast the automobile production process before and after the advent of the assembly line. A primary strategy in dfm involves minimizing the number of parts in a product. The ratio of each model to total output is consistent with customer demand. Introduction several industries utilize lean manufacturing to increase the value of their products and reduce all form of waste. Master of science thesis in the international masters programme automotive engineering.
Plant layout means the disposition of the various facilities equipments, material, manpower, etc. The process allows easier access to the interior assembly of the car. Methodology and applications manufacturing engineering and materials processing chow, wemin on. Students will illustrate in their own words, henry fords 3 principles of assembly. But, the workstation for other component which was required after two operations was a problem.
Various definitions of problems have been established together with different approaches as to the way they are solved. Assembly line design principles using six sigma and. Assembly line design principles using six sigma and simulation. Assembly line balancing by using axiomatic design principles. By following these principles of flexible assembly line design, manufacturers can pursue lean manufacturing in their current operation while also. 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. Dfa is the method of design of the product for ease of assembly.
This is an excerpt from an article in automation world by mark sobkow, vice president of manufacturing solutions. A methodology is proposed that helps to improve the productivity of any production process. 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. With mixed model assembly, figure 4, multiple models are interspersed on the same assembly line. Multicriteria assembly line design under demand uncertainty. The design changes in the panel design according to the different regional requirements make line balancing a critical issue for the efficiency and competitiveness.
Design for assembly dfa has become an increasingly important concept in designing products for todays markets. 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 objective is to minimize total equipment costs, given a predetermined. Efficient assembly line design is a problem of considerable industrial importance. These are shown in fig 2, and categorized with regard to. 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. Design of flexible assembly line to minimize equipment. The design problem addresses the questions of selecting the equipment and assigning tasks to workstations, when precedence constraints exist among tasks.
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