Manual Integrated Design of a Product Family and Its Assembly System

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The product assortment is rapidly changing, the time for innovation is reduced, the demands on the reliability of the production system are increased. Therefore, it is necessary to take an innovative approach to design production and assembly systems working on the basis of high flexibility and elasticity [ 24 , 25 ]. The assembly is most often organized according to the workshop principle which lays the basis for the planning tasks [ 26 , 27 , 28 ]: layout of assembly at common facilities or production lines, product layout depending on when certain types are to be produced , layout of workers at individual operations taking into consideration changes of workplaces after the assembly process, uneven time consumption by individual products, optimization of the order of the manufactured types according to the assembly lines and the occupation of the workers.

The project solution is based on the elaborated theoretical knowledge and comprehensive analysis of the current state of affairs with regard to the problem of product segmentation before the assembly process. Its aim is to propose such an approach that would enable the product to be assembled without the use of complex planning methods. The term innovation [ 31 , 32 ] means the result of the process of creating new things new object. The aim ofthe study is to find out whether existing product segmentation methods vertical and horizontal segmentation can be simply extended by the third dimension, such as the difference in operating times.

Lec 01 Introduction to Product Design and Development

It will help increase the throughput of the assembly line, decrease WIP and increase productivity. The main objective of this case study is to develop a new approach to segmentation of custom assembly products based on the extension of existing segments access methods, allowing to respect the duration of assembly operations. The approach provides on the one hand support for the planning of orders in existing assembly lines and on the other hand it provides the basis for the future design of production systems, whether traditional or digital.

The purpose of the case study is to extend the knowledge base that serves to design and improve production systems. The current performance of the manufacturing systems determines a clear definition of system boundaries [ 33 , 34 ]. The main scientific objective of this case study is based on the scientific research the aims of which is to design the innovative approach to products segmentation in the assembly processes in customized production based on the requirements of the fourth industrial revolution. The proposed model of segmentation products will enable us to achieve the desired added value by optimizing operating cost of production.

The development of sophisticated information technology and intelligent control of business processes is the key to the humanization of human labor. The trend is projected to accelerate depending on the production environment. In production, it is necessary to use information technology with the support of digital engineering control systems , modelling and monitoring systems.

In view of turbulent external environments, it requires a high complexity of supply chain management, which affects the development of software platforms for enterprise resource planning, management of finances and time efficiency of contract performance. The turbulent market and global competition affect the requirement for shorting innovation cycle.

As a result, aspects and complexities of inter-network cooperation cause the growing number of enterprise tasks. Disposition of product models allows for the simultaneous realization of product development and manufacturing, thus reducing the time needed to produce the required dose and perform simulation procedures. Advanced segmentation can split products in the MTO environment to product families that have common features and approximately the same operating times and thus increase the seriality of the already existing assembly process in medium and large-sized companies without the need for big investment in the field of development and adaptation of products to the assembly process.

Individual agents can transmit tasks and in the frame of interactive activities conduct evaluation activities.

Epub Integrated Design Of A Product Family And Its Assembly System

Mutual communication is based on priority rules for the realization of the current transformational needs of the defined roles in meeting the corporate goals. To build adaptable manufacturing enterprise with embedded intelligence a key technology is needed. The mechanism Figure 3 is designed to educate the manufacturing facility in terms of autonomous operation. The emphasis is placed on acquiring knowledge from the external and internal environment, which is necessary for optimization of the product design, manufacturing processes, operations and production plan.

Output parameters are monitored by the sensory disposition which converts the signals into actual data values and initializes activity of detection mechanism to detect abnormalities through a simulation model [ 35 , 36 , 37 ]. The increasing complexity of the system architecture may result in adverse effects on the autonomous control system tasks and system reliability. Manufacturing and assembly systems must be equipped with reconfigurability, which provides for quick configuration of maintenance system and switches generating variants by switching generating tasks depending on the production need of a particular family of workpieces and subassemblied parts by adding or removing functional elements.

Intelligent control mechanisms, as seen in Figure 4 should:.

The aim of the integrated control system is the sustainability of the production company in a competitive environment which includes the prerequisites for development. The purpose of the reconfiguration is to change system functionality and ensure the scalability of the production capacity. Reconfiguration activities can independently add, delete, modify and convert machines handling units based on rapid response to changing requirements and the actual behavior of the system. The system with a given ability may increase the life of production and should offer a cost-beneficial solution in the long term.


When addressing the issue, the authors used available scientific methods from the fields of industrial engineering, adaptive assembly, advanced segmentation, knowledge management [ 38 ], intelligent manufacturing systems, and other advanced industrial engineering methods. In order for the project to succeed, all three elements shall be met: finish the project within the set deadline, in the required quality and within the planned cost range. In various projects, individual elements of the Triple Constraint may differ in terms of scale of importance.

In order for the project and its researchers to work effectively, technical equipment and the means to build a product segmentation model are needed along with the right conditions for experimental testing. The project methodology fit the workplace available at the Department of Industrial Engineering Figure 5 :. Solution respecting the basic elements of Industry 4.

Advantages of segmented products according to the operating time of assembly operations:. Reduction of work in progress and thereby accelerate process flow removal of the moving bottleneck. Reduce the production lead time the increase of the value-added of the product compared to the time spent on the assembly line.

Increase in labor productivity eliminate the waiting for the previous process to finish. Improve the planning process clear rules for identifying product families for assembly lines. Similarity coefficients are the fastest way to assess the similarity of two objects for example, two products based on the number of common or different characteristics.

Build the matrix: Products - Technology types — assembly operations. Calculation of similarities e. Segmentation is further used in an environment design assembly processes. The basic design phases of the new or to be improved assembly process are:. Draft the term structure sequence of operations, performance standard installation. Note: P product , Q quantity , R routing - technological procedures, S service - technological equipment, T time - operating time.

The very core of the scientific research is the issue of applying advanced segmentation that would allow products to be distributed in MTOs to families with a common sign of approximately equal operating times. This will increase the amount of available assembly lines in medium and large-sized enterprises without the need for large investments in the development and adaptation of the assembly process.

There is no need to use complex planning methods that only partially eliminate the effects of external factors in MTO assemblies such as missing material, insufficient capacity of previous processes, product variants, or size of assembly batches.

dblp: Jean-Michel Henrioud

Utilization of the proposed segmentation approach for teaching purposes at the Department of Industrial Engineering is seen as a progressive approach to increase the overall efficiency of assembly processes. It is possible to adapt the number of segments created to a number of assembly lines. Process of sustainable product segmentation in customized assembly is shown in Figure 6. There are some important points to be mentioned:.

The market requires large product diversification from manufacturers, short delivery dates and low prices. This is a clear demand for processes in terms of the need for low costs high productivity , effective flows of information and material, or increased innovation. The typical tasks of workshop planning in the custom assembly are: scheduling products and workers, determining optimal assembly lines and production capacities.

The assembly characteristics may include low repeatability of products, a high variety of products product variants and different working time assembly time consumption, number of assembly operations and their different duration. Products with a longer assembly time slow the previous assembly operation and the queues are formed.

On the other hand, products that do not go through a particular operation may pass through the assembly line more quickly but are inhibited by products that must undergo more complex operations. Difficult assembly process: the balancing of the assembly lines, assigning the staff on the individual operations and assembly lines and maintenance of the specified amount of the finished production may lead to a decrease in the labor productivity.

The price of the product is mostly influenced by the market, and manufacturers have to design their processes in a productive way so that they are based on the competitive production rate of the business. The shortening of the interim periods and the fulfilment of the promises regarding delivery times is crucial for these types of businesses. Companies operating under ETOmanufacturing strategy focus on the storage of common materials, the orders placed are accepted by the development and engineering department based on specific requirements while maintaining efficient production.

These findings provide the basis for the study.

Unbalanced assembly lines, frequent rearrangement of staff at assembly lines and the unstable output from an assembly line are strategic tasks of order assembly planning. Insufficient task planning may result in the following:.