To satisfy the demand for assembly automation, flexible response to diversification of models and production volume changes, the concept of an “Innovative Automation Cell” was thought up as an innovative assembly production system, which can be used in place of conventional conveyor lines—a mode of production in use since the Industrial Revolution. This report describes the “Innovative Automation Cell” concept that can realize more than double production efficiency compared with manual assembly, and outlines of the core technologies. Development results and future issues are also discussed.
Abstract Every organization needs to effectively manage its data collection and analysis process in order to efficiently collaborate on a global scale. This paper describes a model for standardizing the data collection and analysis process and specifically deals with two challenges in this regard: 1) A method for standardization of the nomenclature of different physical parameters measured during a typical engine test. This is essential for processing data from facilities spread across the globe to run them through a standard set of calculations. The process of storing and performing a given set of complex processes on the data while allowing analysts to view the steps of the processing in a transparent intuitive manner is also described in the paper. 2) Building on the first point, the paper also describes a process for performing a standard set of data quality checks on data as it is being collected. This allows for detection of issues in the data on a real-time basis.
Abstract To achieve first time right product in any new part development, the process requires number of trials, skilled manpower, huge cost and massive time. In case of forging process, to develop a new component lot of physical trials are required to be conducted due to the process variations. The need of the hour is shorter development time with highest quality. All these requirements can be achieved with the help of reliable computer simulations. With computer simulation, the process can be optimized and crack analysis can be carried out. Additionally the use of computer simulation in forging process reduces no. of trials, ultimately saves time and energy. The paper deals with forging process optimization by effective use of computer simulation. Existing forging process and modified forging process was simulated.
Abstract The Automated Fiber Placement (AFP) machine layup run time in large scale AFP layup cells consumes approximately 30% of the entire part build time. Consequentially, further reductions to the run time of the AFP machine part programs result in small improvements to the overall cycle time. This document discusses how Electroimpact's integrated system and cell design reduces the overall cycle time by reducing the time spent on non-machine processes.
Abstract As aircraft programs currently ramp up, productivity of assembly processes needs to be improved while keeping quality, reliability and manufacturing cost requirements. Efficiency of the drilling process still remains an issue particularly in the case of CFRP/metal stacks: hot and long metallic chips are difficult to remove and often damage the surface of CFRP holes. Low frequency axial vibration drilling has been proposed to solve this issue. This innovative drilling process allows breaking up the metallic chips in such a way that jamming is avoided. This paper presents a case of CFRP/Ti6Al4V drilling on a CNC machine where productivity must be increased. A comparison is made between the current regular process and the MITIS drilling process. First the analysis and comparison method is presented. The current process is analyzed and its limits are highlighted. Then the vibration process is implemented and its performances are studied.
Abstract In today's aircraft assembly process several new features make drilling operations very challenging according to production requirements. Parts are made of thin or thick multi-material stacks with a large scope to cover and complex assembly sequences. In addition, the current ramp-up in aircraft programs involves to improve productivity while keeping process quality and reliability. In this context robotic solution meets perfectly all these requirements as it is flexible, reconfigurable, fast and agile. Among the possible end-effectors, the Barrel Multi-Function End Effector (BMFEE) appears to be the most flexible solution to allow many different process configurations. The latest developments have been focused on the drilling equipment of this BMFEE. In fact the drilling process efficiency can be constantly improved especially in terms of reliability, quality and productivity. Therefore vibration-assisted drilling system has been integrated into the BMFEE drilling module.
The term “productivity” all too often has becomes a buzz-word, ultimately diminishing its perceived importance. However, productivity is the major concern of any team, and therefore must be defined to gain an appropriate understanding of how a system is actually working. Here, productivity means the level of contribution to the throughput of a system such as defined in the Theory of Constraints. In the field of space exploration, the throughput is the number of milestones of the mission accomplished as well as the potential survival during extreme events (due to failures or other unplanned events). For a time tasks were accomplished by expert individuals (e.g., an astronaut), but recently team structures have become the norm. It is clear that with increased mission complexity, “no single entity can have complete knowledge of or the abilities to handle all matters” .
Measure and Integrate Dynamic Weight of the Moving Truck: ITS Solution to Improve Productivity and Safety
Transport plays major a role in the economic growth of the Nation and social welfare of the community. Wrong practices followed by Transport Operators result in environmental degradation and damage to Transport Infrastructure. To improve productivity and Safety of commercial transport sector in India, it is necessary for all transportation users to calculate, analyze and control the internal and external expenses. Dynamic weight of the moving truck is one of the methods which help to improve environmental quality, increase life of roads and bridges, increase life of the vehicle, enhance productivity and ensures high amount of safety. This paper describes System involving sensing techniques, design and integration, operational and feasibility analysis towards making it affordable, accurate and adaptable. This includes a proposal for regulatory bodies to respond to the challenge of implementation of rules for the productivity and safety of commercial road transport.
Modification of a Plant's Engine Assembly Line to Reduce Employee Movement and Increase Productivity
Modification of the workstations of the automaker engine assembly line in the Betim/MG unit, with a focus on ergonomics, reducing employee movement during the implementation of activities by eliminating activities that do not add value to the product. The entire project was structured according to WCM (World Class Manufacturing) methodology that consists of concepts, principles and techniques for managing operational processes, inspired by the Toyota Production System (TPS), which focuses on wastage elimination. The WCM is supported by technical and management pillars and the one used in this study was the WO (Workplace Organization) that seeks to create an ideal workplace to achieve maximum safety, improved quality, and maximum value in product transformation. The premise for the development of the solutions was the minimum use of resources, prioritizing simplicity of the devices by applying concepts of low cost automation (LCA) leaving the material near the assembling point.
Unprecedented rates in Boeing 737 aircraft production have driven a need for an increase in capacity in fuselage manufacturing and assembly. This paper will discuss the requirements by Spirit AeroSystems to add capacity, and the new and upgraded machinery provided by Broetje Automation in response to these requirements. Production areas found to require additional capacity included galley and entry door skin fastening, as well as frame fastening in upper and lower lobes. Three new Mobile Panel Assembly Cell (MPAC) machines were installed in rapid succession for efficient and flexible production of door panels. For frame fastening of upper and lower lobes, three existing machines were taken out of production one at a time for a comprehensive upgrade resulting in process speed increases of more than 40%.
In addition to providing a wide product range and meeting individual requirements of the customers to make the companies able to orient themselves to the competitive conditions in the automotive industry, properly structuring a capacity-productivity calculation algorithm is of a great importance in obtaining a competitive price advantage. In cases product diversity is too wide, and finished products cannot be measured with a single unit, measuring the production efficiency gets complicated. In addition, the ability to analyze all the inputs and outputs of the production with a single unit based on the same value for enterprises instead of analysis of combined units carried out based on a single perspective when calculating the production efficiency of the enterprises underlies continuous improvement and being able to set goals for the processes.
The high manufacturing-rate of CFRP-parts for aerospace components is demanding for efficient solutions in the field of automated systems and intelligent toolings. Combining these two factors the production of CFRP-parts is becoming more efficient than using this separately or even better than using manual processes and conventional toolings. The department of Production Systems within Premium AEROTEC has developed both self heating toolings for preforming and curing of CFRP-parts as w ell as automated handling and draping systems for CFRP-material (i.e. dry laminates or prepreg). This will be presented in this article.
A recent Gartner Dataquest study predicts that the total worldwide automotive semiconductor market will grow from $20.1 billion in 2007 to $25.9 billion by 2010. The study also predicts that revenue from automotive usage of FPGAs will triple to approximately $312 million during that same period. Many of these FPGAs will be deployed in safety applications such as back-up cameras, lane departure warning systems, blind-spot warning system, and adaptive cruise control. FPGAs will also be deployed in next-generation engine electronics, emissions control, navigation, and entertainment applications. Automotive systems engineers are adept at using Model-Based Design for implementing some of these embedded applications on DSPs and microcontrollers. Many of these engineers are new to FPGA design and waking up to a fragmented workflow that is making it harder to meet time-to-market and cost objectives.
Remanufacturing, or Reman, is an industrial process whereby used products referred to as cores are restored to useful life . The automotive reman products in the current state account for two thirds of all reman according to Steinhilper . The growing “Green” awareness can force the automotive OEMs (Original Equipment Manufacturer) to demand more reman products from the OE suppliers in their contracts. Also reman makes a lot of economic sense for the customers and the OE suppliers since the reman products are sold at an average price range of 60% of the price of a new product . This paper is a case study of how the authors applied lean principles to increase the project throughput through the reman engineering organization to meet the growing demand for reman products. Extensive literature exists on how to apply lean in the plant floor. But very few papers talk about how to apply the same lean principles in the office environment even before it hits the plant floor.
The goal of this research work is to explore the energy savings that may result from productivity improvement recommendations. The productivity improvement recommendations on setup time reduction and finished goods inventory reduction were taken from Industrial Assessment Center (IAC-WVU) and Industries of the Future (IOF-WVU) databases at West Virginia University (WVU) and analyzed to evaluate the corresponding energy savings. A simulation analysis was performed to compare the peak energy demands (kW) in the present and proposed scenarios for the setup time reduction recommendation. It was found that productivity improvement recommendations can result in significant energy savings (2% to 4%).
While the industry has recognized the value of modeling and code generation, the role of verification has taken a limited second tier role. Model Based Testing (MBT) is typically discussed in the context of automation of testing activities to eliminate the burden of generation and execution of tests. Unfortunately, this objective of effort minimization has skewed solutions away from using quality as a guiding metric. Alternatively, we have identified the simple objective of increasing the quality of testing practices and productivity of developers. In the following paper we introduce the integration of traditional software quality practices of functional, unit, and regression testing with the automated, model-driven world. This approach enables a quantitative approach to model driven software quality. The result is a robust technique that enables confident use of model-based development for production applications.
Lean Manufacturing philosophy resulted from the best practices combinations used in identifying and eliminating wastes along the manufacturing process, looking for simultaneously high quality, low cost, shorter lead-time and higher flexibility. Due to high competitiveness in first rate industries, mainly automotive, there is a great effort in applying Lean Manufacturing pfilosophy in deeper levels. When targeting full Lean Manufacturing implementation, product concept plays an important role on its efficacy. On the other hand, there is a lack of elements to support a most efficient product development while foccusing Lean Manufacturing philosophy implementation. Present article brings forward, in the form os guidelines called Design for Lean, a systematization of the best practices for product design that will support the development of products with focus on Lean Manufacturing implementation.
The development of flexible fuel vehicles usually puts exhaust emissions in the critical path as more tests are required to cover different fuel blends. An informal survey showed that most engineers still use standard spreadsheets to analyze emissions data, usually a cumbersome, tedious and unproductive process. This paper describes the specification and development of a dedicated exhaust emissions data analysis tool, designed to improve productivity during the development phase. Through the combination of emissions and vehicle data, the tool automatically generates a set of reports that can be customized according to the best practices of each organization. The data analysis of an exhaust emissions test is performed using traditional methodologies and then compared to the new tool to emphasize the productivity gains.
Heijunka production, a core element of Toyota Motor Company's well-known Just-in-Time production methodology, was developed to deliver vehicle orders in the shortest lead time, with minimum inventory and maximum production efficiency. It achieves this by averaging (“leveling out”) production quantity and model. Adaptable to any production environment, the Heijunka production is an effective tool for industries with low-mix/low-volume production systems. In our case study, a manufacturer of interior subassembly items for commercial jets implemented Heijunka production and achieved significant improvement in inter-process inventory, lead time and productivity. Most notably, inter-process inventory was reduced to 20% in just five years.
The purpose of this paper is to explore the challenges and opportunities for auto companies interested in setting up operations in emerging markets. One of the most widely accepted best practices is a concept called LeanThinking (1). This discussion focuses on the implementation of LeanThinking in China. In essence, LeanThinking is a broad management system; when applied to the manufacturing business sector, it is called lean manufacturing.
Recently developed portable tools have proven themselves capable of feeding and installing fasteners automatically. They eliminate the entire manual processes attendant to the selection and manipulation of fasteners. The fasteners are either stored in remote cassettes or in storage built into the tools themselves. The paper will describe the various means of storing and automatically selecting the fasteners. Ergonomic enhancements, that offer reduced physical stress and provide a safer working environment, will be demonstrated. The configuration of two existing configurations, one suitable for Hi-lites© and the other for solid rivet installation, will be described. The details of the actual installation process and the computer interaction available in support of the installation processes will be described, along with the effect of the man/machine system on the flexibility, predictability and cycle time reduction of the process.
The Kanban system is an essential tool for implementing a Just-in-Time (JIT) production process, which enabled Toyota Motor Company to achieve the highest productivity in the automotive world. Furthermore, it can be also a useful management method in other types of industries as well. In future, many organizations and business other than the automobile industry will discover the benefits of the Kanban system in achieving what we call “lean operation”. The Kanban system is an integral part of an overall Kaizen (“continuous improvement”) undertaking, acting as a visual control tool. Any JIT production process incorporating a Kanban system requires Heijunka (“leveled production”). This report includes an overview of an actual Kaizen operation incorporating a Kanban system at a sub-assembly process for aircraft components. After implementing the Kanban system, the average inventory cost was reduced by approximately 42% in one year.
Model-based systems development relies upon the concept of an executable specification. A survey of published literature shows a wide range of definitions for executable specifications [1, 2, 3, 4, 5, 6, 7, 8, 9 and 10]. In this paper, we attempt to codify the essential starting elements for a complete executable specification-based design flow. A complete executable specification that includes a functional model as well as test cases, in addition to a traditional prose document, is needed to transfer requirements from a customer to a supplier, or from a systems engineer to electrical hardware and software engineers. In the complete form demonstrated here, sub-components of a functionally-decomposed system manifest as modular reuse blocks suitable for publication in functional libraries. The overarching definition provided by product architecture and by software architecture must also be harmoniously integrated with design and implementation.
COOPERATION BETWEEN INDUSTRY AND ACADEMY CAN PROVIDE GAINS IN PRODUCTIVITY, IMPROVING THE STRATEGICAL COMPETITIVENESS
Summary Brazil is undergoing a positive phase. It is time to question ourselves about how have we come to this point and how is this going to evolve. Our country went, in little more than a decade, since the early Nineties, from a closed economy, with almost 50 years of experiments based on the import substitution model, for a wide open relation with the rest of the world, followed by internal adjustments (privatization of state owned companies, regulating agencies, some structural reforms) that led to the current configuration. Today a relatively mature relation with the rest of the World prevails, subject to the typical instabilities of the globalization, in which the Country, however, has been apt to participate of the international relations both as an exporter as an importer of goods and services, besides serving as a productive platform for many worldwide products.
Accurate measurements of productivity and quality are essential for balancing workload, creating predictable schedules and budgets, and controlling quality. Traditional software development processes include well-established methods for measuring productivity and quality. These include Lines of Code (LOC). With the introduction of Model-Based Design, organizations require a different measure of the software development process.
High-pressure die casting is a highly productive process that yields near net-shape castings at a relatively low cost. One disadvantage of die casting, however, is residual porosity that is inherently present in the castings. Semi-solid die casting is a method that is superior to die casting as it relates to porosity but has historically been a more expensive process. This is due to the higher cost of the billet feed material and the inability to easily recycle billets and runners. Slurry-on-Demand is a new semi-solid casting process that develops the semi-solid slurry directly from the liquid, thereby eliminating the cost penalties intrinsic to the billet semi-solid process. This paper will describe the Slurry-on-Demand process in detail and present case studies comparing the casting of large components using both Slurry-on Demand and conventional high-pressure die casting. It will also provide examples of quality improvements achievable by the Slurry-on-Demand process.
The integration of robot system operation is the most important and interesting issues for robot end users. Increasing robot operations by a growing variety of robots, applications, and models is a serious problem in maintaining high productivity and reducing maintenance cost. In the practical development of the Toyota global body assembly line (GBL), we designed a special robot operation and man-machine interface system based on the experience of robot operators. The Toyota Integrated Robot Operation System (IROS) offers remarkable advantages in the application of practical body assembly lines.
The need to measure the relative value of business and commercial aircraft and how the designer/analyst can formulate an initial idea of what should constitute a satisfactory array of aircraft design specifications is presented. This is achieved firstly through the establishment of relevant productivity indexes using key target parameters or macroscopic objective functions. To complement this, a new primal objective function construct designated as the Airframer Paradigm is reviewed in order to ascertain how much a given set of design specifications are worth to the market. Finally, an overview of how new technologies and utility features affect the value of aircraft as well as an assessment of design philosophies for the present and future are discussed.
Given the low business safety margins of today's highly competitive marketplace and companies' inevitable efforts towards cutting cost and continuous improvement, the automotive industry, as well as other manufacturing arenas, are in a deep need for developing quantifiable definitions of their relevant performance improvement criteria. Manufacturing operations often represents the core of a company's business strategy. Hence, this paper describes an analytical and a simulation-based integrated methodology for determining Manufacturing Performance Metrics (MPMs) at both process and system levels. The proposed methodology focuses on determining MPMs associated with four key Industrial Engineering criteria: Productivity, Quality, Reliability, and Effectiveness (PQRE). Other criteria such as Cost and Safety, which are commonly used in conjunction with the PQRE criteria for systems design and improvement, are not the focus of this paper.
In recent years manufacturing and quality are not separate concepts. At first these concepts were thinking different step and process. In this world of tightening competition among manufacturer at a national and international level, the question of quality of important emerges as a serious issue. This concern is shared by all members of manufacturing and consumer. The manufacturing sector today, quality standards (ISO 9000) registration could become a requirement for any institute of standard wanting to do business in the international and/or national market-place. Therefore quality education and assurance are very important factors in higher education and engineering faculty. Quality is dynamic interaction and changeable. In the world of engineering education has been changing rapidly. This study about quality of manufacture, standards and quality system in Turkey and Sakarya on the basis of engineering faculty with some questionnaires about industrial company.