Laboratory for Machine Tools and Production Engineering

Transcription

Produktionsmanagement I (Prof. Schuh)
Lecture 06
Laboratory for Machine Tools and Production Engineering
Chair of Production Engineering
Prof. Dr.-Ing. Dipl.-Wirt. Ing. G. Schuh
Production Managment I
Lecture 6
Planning and Organisation for Manufacturing and Assembly
Contact:
Dipl.-Ing. Sebastian Ivanescu
Steinbachstr. 53B
Room 515
Tel.: 0241-80-20394
[email protected]
Page 1
Lecture 06
Table of contents of lecture 6:
1.
Table of contents
L6 Page 2
2.
Abstract
L6 Page 3
3.
Glossary
L6 Page 4
4.
Highlights of the lecture
L6 Page 5
5.
Lecture
Planning for Manufacturing and Assembly
L6 Page 6
Manufacturing
Functions and Equipment
L6 Page 9
Manufacturing Principles
L6 Page 10
Manufacturing Types
L6 Page 12
Manufacturing Planning
L6 Page 15
Description of a Machining Task
L6 Page 16
Derivation of Technology Requirements
L6 Page 18
Disposition of a Manufacturing Sector
L6 Page 20
Conclusion
L6 Page 21
Trends
L6 Page 22
Assembly
Characteristics and problems of assembly
L6 Page 23
Tasks of assembly planning
L6 Page 26
Definition of assembly tasks
L6 Page 27
Determination of the assembly structure
L6 Page 28
Determination of the assembly areas
L6 Page 29
Assembly organisation forms
L6 Page 31
Bibliography
L6 Page 34
Page 2
Lecture 06
Schedule:
Topic
No.
Date
V1
Technology Management I
20./21.10.2008
V2
Technology Management II
27./28.10.2008
V3
Product Planning & Engineering
03./04.11.2008
V4
Variant Management
10./11.11.2008
V5
Process Planning
17./18.11.2008
V6
Planning for Manufacture & Assembly
24./25.11.2008
V7
Operations Management
01./02.12.2008
V8
Materials Management
08./09.12.2008
V9
Lean Production - Production Systems
15./16.12.2008
V10
Production Strategies
05./06.01.2009
V11
Buisness Modelling
12./13.01.2009
V12
Prozess Modelling
19./20.01.2009
V13
The Industrial History: From Taylorism To Virtual Factory
26./27.01.2009
Responsible
Mr. Haag
0241 89 04275
Mr. Nollau
0241 89 04271
Mr. Jung
0241 80 27392
Mr. Bartoscheck
0241 80 28203
Mr. Pulz
0241 80 27388
Mr. Ivanescu
0241 80 20394
Mr. Quick (fir)
0241 47705-425
Mr. Helmig (fir)
0241 47705-435
Mr. Deutskens
0241 80 27380
Mr. Kuhlmann
0241 80 28197
Mr. Baumann
0241 80 28398
Mr. Ziskoven
0241 80 27378
Mr. Gaus
0241 80 28477
Page 3
Lecture 06
Lecture landscape
Production management II
•
•
•
•
•
IT in Production management+ Dig. Fab.
Customer Relations Management
Enterprise Ressource Planning
Supply Chain Management
Product Lifecycle Management
Production-oriented- and
Assembly-oriented Construction
• Construction tasks in small groups
• Construction examples
• Constructions guidelines
Innovation managment
mit Dr. Wiedeking
• Integrated management tasks
• Product- and productprogram planning
• Organization and behaviour of employees
Production management I
V1
V2
V3
V4
V5
V6
V7
V8
V9
V10
V11
V12
V13
Technology Managment I
Technology management II
Produktplanning/Construction
Variant Managment
Work planning
Plannning of Manufacturing & Assembly
Operations controll
Material managment
Lean Production - Production Systems
Production strategies
Business modelling
Process modelling
Industrial history
Cost managment in
production
• Cost calculation
• Capatital budgeting
• Financial statements
Capital budgetting
• Tooling planning
• Technology planning
• Cost calculation
© WZL/Fraunhofer IPT
Facility planning
• Tooling planning
• Storage- & Transportplanning
• Employee planning
Page
Seite 4
Page 4
Lecture 06
Glossary
Manufacturing concept:
Logical and spacial arrangement of production
means and work stations; divided into job
shop, group and continous flow
manufacturing.
Assembly concept:
Logical and spacial arrangement of the
assembly work stations; divided into site
installation, group-, line-, time-phased
production line and continuous flow assembly.
Job shop manufacturing:
Arrangement of production means and work
stations according to the manufacturing
method (methods of the same kind are
centralized into one „competence centre“);
suitable for frequently changing work pieces
and small scale production.
Group manufacturing:
stations according to the product (all methods
needed to machine a group of work pieces are
logically and spacially combined); suitable for
recurrent manufacturing methods with
frequently changing variants.
Continous flow manufacturing:
stations according to the sequence of the
manufacturing processes of a work piece (flow
principle); suitable for recurrent/ similar
manufacturing processes and large scale
production.
Small scale production:
Production method for small quantities of
products; usually order related.
Large scale production:
Production method for large quantities of
products; usually not order related, but
customer specific variants are possible (e.g.
automotive industry).
Performance production arrangement: Form of assembly organisation with stationary
assembly objects (Site installation or Group
assembly).
Continous flow arrangement:
Form of assembly organisation with moving
assembly objects (Line assembly, Timephased production line assembly or
Continuous flow assembly).
Page 5
Lecture 06
Abstract
The objective of the lecture is to impart the principles of manufacturing and assembly
planning.
For this purpose, the basic functions of the production fields Manufacturing and Assembly
are presented, the manufacturing equipment and types of organisation are described and
the procedure of planning the two above mentioned fields is explained. This means in
detail:
• to present the functions and manufacturing equipment of the manufacturing sector and the assembly area as well as their organisation in the operational
process
• to characterise the different manufacturing types (individual production and
series production)
• to show the systematic procedure of manufacturing and assembly planning
• to describe the tasks of planning
• manufacturing and assembly structures
• types of organisations
• production means, personal, material to be processed
• Describing the addatives for planning of Manufacturing and Assembly
In addition to that the future design trends are to be shown.
Particularly the following terms will be explained and defined in this lecture
- functions of manufacturing,
- manufacturing equipment,
- manufacturing qrganisation forms,
- manufacturing types,
- manufacturing principles,
- technology requirements and specifications
- composition of part families,
- functions of assembly,
- production related data,
- product related data,
- sub-assembly,
- main-assembly,
- assembly organisation forms,
- forms of material provision
Page 6
Lecture 06
Highlights of the lecture
Manufacturing principles
Suitability of manufacturing methods
Fields of application of different manufacturing concepts
Differences between Manufacturing and Assembly
Coherency between product- and assembly structure
Page
Seite 7
Page 7
Lecture 06
Structuring
1
Meaning of the categories assembly and manufacturing
2
Planning the Manufacturing
3
Planning the Assembly
Page
Seite 8
Page 8
Lecture 06
Planning of Manufacturing and Assembly
Business management / Controlling
Purchasing
Design
Operations
planning
Types of organisation
Manufacturing
Assembly
Planning of facilities/
production means
Sales
Trends
?
[Year]
1999 2001 2003
Page
Seite 9
Annotations:
The lecture has 2 focuses:
• Manufacturing
• Assembly
First of all, the issue of manufacturing is addressed.
Hereby particularly
• organisation forms
• aspects of planning and
• trends
will be elaborated.
Page 9
Lecture 06
Effects of Manufacturing and Assembly on Preceding Areas of
Production
Manufacturing process
Design
Drawing up of manufacturing
documents
Design
modifications
Operations planning
Modification of
machining
procedures
Operations planning
Operations management
Machining
possibilities
Manufacturing
Manufacturing of
single parts
Assembly
Assembly of single
parts and modules
Products
Page
Seite 10
Annotations:
On the part of manufacturing e.g. targt for design and process engineering:
• maximum achievable accuracy
• biggest possible workpiece measurements
Resultant are the performance data for the determination of the target time and process sequence.
Page 10
Lecture 06
The significance of the divisions Manufacturing and Assembly
Net added value [%]
100
95
65
35
25
5
Supplier A
Supplier B
Purchasing
Design
Operations
planning
Manufacturing
Assembly
Sales
Page
Seite 11
Annotations:
The value creation within the manufacturing chain is the biggest one in the fields of manufacturing and
assembly. Therefore, these areas of the manufacturing process are of utmost importance.
Page 11
Lecture 06
Structuring
1
2
3
Page
Seite 12
Page 12
Lecture 06
Functions and Equipment of Manufacturing
Functions
Provision of
information
Staging of
workpiece
Workpiece
change
F
Measuring,
checking
Buffering of
workpiece
Tool change
Process
monitoring
Machining
Removal of
chips
Manufacturing equipment
Manufacturing
System
Machine Tools
Tools
Fixtures
Page
Seite 13
Annotations:
Page 13
Lecture 06
Comparison of different Manufacturing Principles
Job shop
manufacturing
Continuous flow
manufacturing
Group manufacturing
Typical arrangement
Machining cell
Machine shop
Line of machines
Structure of the manufacturing sector
Raw materials stock
Raw materials stock
D
D
B
B
D
B
D
Raw materials stock
D
D
F
D
D
D
B
F
S
F
B
B
B
F
F
B
F
F
F
F
S
S
F
S
B
F
Finished-parts store
Criteria of structure:
Combination of the same
type of machine tools
Combination of the necessary
machining procedures for
one family of workpiece
Operation sequence of one
family of parts determines
the flow line
Page
Seite 14
Annotations:
There are three basic principles of manufacturing:
• Job shop manufacturing:
frequently changing workpieces and small scale production.
• Group manufacturing:
recurrent manufacturing methods with frequently changing variants.
• Continous flow manufacturing:
recurrent/ similar manufacturing processes and large scale production.
The criteria for manufacturing principles are therefore technological, process-related or organisation-related.
Besides the basic manufacturing principles, hybrid forms can be generated.
Page 14
Lecture 06
Suitability of different Manufacturing Principles
Criteria of machining
Principles of manufacturing
Organisation
Procedure
Workpiece
Job shop
manufacturing
Group
manufacturing
Continuous flow
manufacturing
Similarity of form
a
Sameness of form
a
Correspondence of range of dimension
a
Technological similarity
a
Complexity of process per workpiece
a
Uniformity of processes per workpiece
a
Uniformity of process sequences per workpiece
a
Big number of processes per workpiece
a
Great differences in processing times
a
Big quantity of items per lot
a
High lot frequencies
a
Great demands on work contents
a
Great demands on control and schedule
monitoring
Great demands on allocation of costs
A
b
a
Legend:
- Low suitability
- Limited suitability
- Good suitability
Page
Seite 15
Annotations:
Suitability of manufacturing principles against the background of certain criteria of evaluation.
Page 15
Lecture 06
Comparison of Manufacturing Types
Frequency of repetition
Frequency of repetition
Example:
Plant
construction
<24
=
Average lot size
Year
Example:
Machine tool
manufacturers
Mass production
Large scale production
<12
Small scale
production
Example:
Electronic
hardware manufacturers
Example:
Home appliances
manufacturers
<1
One time production
101
50 102
103
104
Produced annual quantity of items
Page
Seite 16
Annotations:
The delimitation with regard to the manufacturing type orientates itself by e.g. the frequency of repetition/
the average lot size of the products. The limits are vague, the quantities of items are only guidelines.
Page 16
Lecture 06
Characteristics of Small Scale and Large Scale Production
Individual and small
scale production
Large scale and
mass production
Order data
Lot size
small
big
Annual quantity of items
small
big
frequently
rarely
small
big
low
high
Proportion of operating time
low
big
Proportion of side operation time
big
small
average
small
Manufacturing equipment
Changeover of manufacturing
Capacity utilisation
Space utilisation
Manufacturing process
Proportion of changeover time
Page
Seite 17
Annotations:
Individual and small scale production and large scale and mass production differ in:
• order data
• manufacturing equipment
• manufacturing process
Page 17
Lecture 06
Fields of application of different Manufacturing Concepts
Field of application:
- minimum quantities of items
- little similarity of parts
Number of variants
Example: Prototype
manufacture
- frequent order change
- little similarity of parts
Example: Tool manufacturing
Non-interlinked
NCmanufacturing
Manufacturing
cell
Machining
centre
Flexible
manufacturing
system
- frequent order changes
- small quantities of items
Example: Aircraft construction
Flexible
manufacturing
line
Transfer line
Quantity of items per variant
- average quantities of items
- complex machining task
Example: Housing
manufacturing
- average or big quantities of items
- great similarity of parts
Example: Engine manufacturing
- large-batch and mass
production
- rare order change
Example: Automotive industry
Page
Seite 18
Annotations:
Comparison between number of variants/ quantity of items per variant and corresponding fields of
application.
Page 18
Lecture 06
Manufacturing Planning
Manufacturing planning
Analysis of potential
• performance data
• degree of automation
• add-ons
Analysis of potential
• principles of manufacturing
• conveyance frequency
• priority rules
Description of machining task
Description of machining task by means of geometric,
technical and order-related parameters
Derivation of technology requirements
according to types and characteristics of
necessary manufacturing equipment
Disposition of manufacturing sector
Accompanying evaluation
Analysis of product
• product structure
• order data
• criteria of selection
Determination of capacity requirements and of the
arrangement structure of manufacturing equipment
Page
Seite 19
Annotations:
Gradual disposition and specification of individual performers:
• product analysis
• description of the machining task (requirements profile)
• examination of capacities (including analysis of potentials)
• arrangement structure (including analysis of potentials)
Each planning step is described in detail in the following.
Page 19
Lecture 06
Essential parts belonging to a
Comprehensive Description of a Machining Task
Derived machine
requirements
Machining task
Material: CK 45
Elementary form:
Forging blank
• Precisions/ procedure
• Speed graduations
• Performance
• Rates of feed
Technological data
• Material/hardness/
machining property
• Tolerance requirements
• Heat treatment
• Pre-machining/ fine
machining
Gear tooth
forming
Cone
Geometry of moulded
elements
Organisational data
•
•
•
•
Parts families
Quantities of items
Number of variants
Lot size/ frequency of
repetition
Geometry of
workpiece
• Bends/ radii
• Size
• Tolerances
• Type and quantity of
moulded elements
• Bevellings/ legs of
trajectory
• Type of external form
(e.g. uphill casted on one
side)
• Discontinuities of
diameters
• Rotational part with/
without deviations
Page
Seite 20
Annotations:
Parameters for the description of the machining task are:
• geometric data,
• technological data,
• organisational data.
The geometric description of a workpiece depends e.g. on the fact if a metal-cutting or a non-cutting
machining task is planned.
Page 20
Lecture 06
Manufacturing of part families
Geometric similarity
with regard to:
Form
Technological similarity
with regard to:
Chucking means
Machining Measuring means
Dimension
Workpiece system
Classification system
Manufacturing of
part families
Higher productivity
Rationalisation
of design
Adapted
production
means
Higher degree of
automation
Page
Seite 21
Annotations:
If it is not possible to produce sufficiently big lots of components of one machining task, a formation and
manufacturing of a family of parts should be realised.
With this effect, the reduction of changeover, retooling and setup works is made possible.
Page 21
Lecture 06
Overview: Processing Requirements – Machine Requirements
Analysis of
workpiece
Organisational data
Geometry of moulded elements
Technological data
Geometry of workpiece
Derived machine requirements
Processing requirements overview
Balancing
Machine requirements overview
Maximum workpiece diameter
Maximum machine-tool output
Maximum workpiece length
Maximum machine accuracy
Page
Seite 22
Annotations:
The machine has to meet the requirements that are necessary to carry out the machining task.
Page 22
Lecture 06
Selection of a suitable Type of Manufacturing
Requirements Profile of
Batch Production
Short throughput
time
Non-interlinked
NC-machines
Little
manpower
requirements
Low
investment
High
quality
High
flexibility
Transfer line
High
productivity
Manufacturing island
Flexible
manufacturing
line
Machining
centre
Flexible
manufacturing
system
Legend:
Requirements profile
Performance profile
Performance profile of manufacturing types
Deficiencies
Page
Seite 23
Annotations:
The selection of manufacturing type depends on the criteria shown in the figure. The requirements profile
has to be completely covered by the performance profile.
Page 23
Lecture 06
Derivation of the Machine Plan
Analysis of
parts spectrum
Determination
of operation
sequence
131
Calculation of
capacity
requirements
Calculation of
number of
machines
132
Necessary capacity
requirements
Representative
workpiece
spectrum
Standard operation
sequence
Milling
• Alternative
operation
sequences
• Clearing-up
h/a
Drilling
• Quantity of
items
• Machining
requirements
13
Turning
12
Capacity
availability per
machine
Capacity balancing
Capacity balancing
Number of
machines
Page
Seite 24
Annotations:
The steps shown in the figure have to be taken when selecting the machines. Should the situation arise,
some corresponding iterative loops will have to be gone through.
For further information on this topic compare the lecture „Fabrikplanung“.
Page 24
Lecture 06
Results of the Lecture Part Manufacturing
Business management / Controlling
Purchasing
Design
Operations
planning
Manufacturing
Functions of manufacturing equipment
Principles of
manufacturing
Manufacturing types
Overview processing
requirements vs.
machine requirements
Derivation of a
machine plan
Assembly
Sales
Planning phases of
manufacturing
Trends:
?
Page
Seite 25
Annotations:
Page 25
Lecture 06
Structuring
1
2
3
Page
Seite 26
Page 26
Lecture 06
Automation levels of manufacturing
Company objectives
• Throughput time reduction
• Reduction of personnel costs
4
• Increase of production quality
Automation levels
• Increase of system transparency
• Increase of flexibility
3
• Reduction of
changeover times
Workpiece conveyance system
Tool conveyance system
Disposal system
Workpiece changing system
Tool changing system
Warehouse system
2
Information flow control
Material flow control
Measuring system
Monitoring system
1
NC-control
Starting point:
Conventional production facilities
Increasing
integration
Page
Seite 27
Annotations:
Especially for small and medium-sized businesses it is very difficult to manage the technical, organisational
and economical burdens that arise during the implementa-tion of flexible production systems. On the basis
of a presently conventional ma-chine technology the production facilities can be automised in four stages.
General trends are:
• modularisation of components,
• automation of machinery and equipment.
The displayed dependencies are results from an industry project with Fichtel & Sachs.
Page 27
Lecture 06
Problems of Planning and Controlling the Assembly Compared with
Machining by Stock Removal
Manufacturing
Finished parts
Finished
parts
sawing turning
milling
Planning and
control task
For the most part clear
operation sequence
Assemble
Finished parts
• Comparison
• Estimation
Determination of time
• Calculation of
relevant factors
• Time
Coordination
• Raw part
• Personnel
Information
• Production
means
Finished parts
Networked operation
sequence
Operation sequence
• Average value
tables
• Company-specific
guideline values
• Standard time files
Assemble Assemble Product
Single part
Zeit
Raw parts
Assembly
• Single part
• Module
• Personnel
Information
• Production means
• Area
E
Product
Page
Seite 28
Annotations:
In the following, manufacturing and assembly will be contrasted:
The assembly process is networked by the material that is brought together; the necessary motion
sequence is often complicated.
The deterministic planning is usually very complex; e. g. the determination of times has to be estimated.
Page 28
Lecture 06
Functions of the Assembly System
According to:
Kuka
According to:
DEXION
Input
Assembly process
Single parts
Modules
Secondary
functions
Main
functio
n
M
Assembling
According to:
Eisenmann
Output
Products
A
Controlling
Handling
Storing
Adjusting
Conveying
According to: Renk
According to: Gildemeister
According to: Maho
Page
Seite 29
Annotations:
For the individual and small scale production usually simple, versatile all-purpose tools are used.
For large scale and mass production increasingly automated assembly devices and fixtures specially
adjusted to individual products are used.
Page 29
Lecture 06
Characteristics and problems of assembly with different Production
Conditions
Individual and small
scale assembly
Large scale
assembly
Parameters of assembly
Multiplicity of parts
Parts geometry
Lot sizes
High
Variable
Small
Low
Constant
Very big
Dependencies on customer requests
Work instruction
High
Rough
Low
Detailed
Discontinuously
Dependent on order
Continuously
Program-oriented
Material flow
Material to be processed
External feature
Almost exclusively manual assembly
Increasing mechanisation and
automation of processes
Typical problems
- long throughput times
- many missing parts
- Capacity constraints
- regarding: Personnel
Area
Test benches
- longer breakdown and side
operation times due to:
- conveyance works
- adaptation works
- time-consuming planning of
procedure in case of
- modifications of production
conditions
- design modifications or new
products
- material planning problems
concerning staging
- in case of station failure considerable effects on the productivity
Page
Seite 30
Annotations:
Highly complex products are usually manufactured in small lot sizes. Their production demands for qualified
personnel.
For easier assembly tasks and large lot sizes the automation of the assembly processes is desirable from
both the technical and the economical point of view.
Page 30
Lecture 06
Tasks of Assembly Planning
Requirements for planning the assembly
Room
Energy
Information
Constraints
Aims
Sales
Market share
Costs
Determination of
assembly levels assembly phases
- final assembly
- module
assembly
-
- pre-assembly
- main assembly
- subsequent
assembly
-
Definition of
assembly tasks
Determination of
assembly structure
Determination
of assembly
Product data
- weight
- dimensions
- assembly
- operation
sequence
Production data
- product variants
- quantity of items
Determination of
organisationform
- Site installation
- Group assembly
- Planning of production means
- Planning of personnel
- Determination of assembly process
Disposition of assembly
Page
Seite 31
Annotations:
Firstly the resources and the potential of a company are identified.
After this, the assembly layout is designed in four steps. Each one of these four steps will be explained in
detail in the follöowing.
Page 31
Lecture 06
Data for the characterisation of an Assembly Task
Products to be assembled
P1
Production-related
data
P2
P3
P4
P5
Product capacity
profile
P7
Product-related
data
- Logical interdependency
of assembly activities
Capacity
requirements
Quantity
of items
P6
Time
- Number of different
products
- Gradients of quantity of
items
- Production times
Time
- Capacity requirements
- Variant-specific capacity
shares
- Single parts
- Weight
Page
Seite 32
Annotations:
Description of the assembly task by means of:
• production related data,
• capacity profile,
• product related data.
Page 32
Lecture 06
Subdivision into sub-assembly and main assembly
Initial information
- Quantity of items
- Variant code
- Lot sizes
Product structure
Subdivision into
Constraints
- Technique
- Technology
- Separation of manual and
automatic sectors
Organisational
sub-assembly and
Centralised
Line 1
main assembly
Sub-assembly A
Organisational
- Order-oriented
- Programme-oriented
- Consumption-oriented
Line 2
Single-stage
Decentralised
MA
SA 1
SA 2
Sub-assembly A
Multi-stage
Sub-assembly B
Legend: SA: sub-assembly
MA: main assembly
MA
SA1
SA2
SA3
Page
Seite 33
Annotations:
Thje single most important influencing factor for the delimitation of the sub-assembly areas is the product
structure.
Centralised SA:
• small number of necessary fixtures/ devices
• in case of a breakdown: impact on all production lines
Decentralised SA:
• better availability as the installations are redundant
Page 33
Lecture 06
Aims of separating Sub-Assembly Areas from Main Assembly Areas
Examples
Aims
- Reduction of throughput
time
SA
- Decoupling of subsystems
Buffer
MA
Manual sub-assembly
Automatic main assembly
- Concentration of variant
effect
- Simplification of
automation possibilities in
subsystems
- Interlinking equipment
matched for basic
components
- Good accessibility to
assembly object in preassembly areas
- Possibility to shift
assembly volumes to
suppliers
Legend: SA = sub-assembly
MA = main assembly
Examples
SA
MA
t
Saving of throughput time
Variant-independent SA
variant-dependent MA
MA
SA
MA
Staging of
bought-in
modules
Page
Seite 34
Annotations:
Page 34
Lecture 06
Coherency between Product Structure and Assembly Structure
Efficient determination of product structure
Product structure
Assembly structure
Product
Which part
UN
CP
CP
SA
SA
S
P
S
P
Legend:
UN
CP
CP
SA
S
P
UN
CP
SA
SP
is assembled
CP
Intermediate
store
When
Where
SA
S
P
Final assembly
How
Subassembl
y
Subassembl
y
Subassembl
y
With whom
A
B
C
S
P
= Unit
= Component
= Subassembly
= Single part
By whom
Warehouse
Page
Seite 35
Annotations:
A systematic subdividing of a product into components that can be pre-assembled and ideally preliminary
tested for their operatability is a precondition for a „good“ assembly structure.
Page 35
Lecture 06
Kinematic Alternatives of Organisational Forms in Assembly
Performance production
arrangement
Advantages
Move
and
characteristics
disadvantages
Site
installation
Group
assembly
Continuous flow arrangement
Line assembly
Stationary assembly objects
Stationary
workstations
Moving work
stations
+Good feasibility of
special orders
+...
- Extended capital
tie- up
- ...
+Modest area
requirements
+...
-High control costs
- ...
Legend:
-mechanical assembly
equipment
-manual work
station
Time-phased
production line
assembly
Continuous
flow
assembly
Moving assembly objects
Moving assembly
objects
Stationary
work stations
Fließprinzip
Moving work
stations
+ Low qualification standards
+ ...
- High planning costs
- ...
- assembly object
- object move
+Great transparency
of assembly
process
+...
- Low suitability for
special orders
- ...
- work station move
Page
Seite 36
Annotations:
There are four basic assembly organisation forms:
• site installation
• group assembly
• line assembly
- line assembly without cycle time
- time-phased production line assembly with cycle time
• combined continous flow assembly
Page 36
Lecture 06
Types of production means in the Assembly Department
Types of production means in the assembly department
Conveyance
equipment
• Roller
conveyors
• Chain
conveyors
• Monorails
Storage
equipment
• Warehouse
• Bunker
• Hoppers
• Shelves
Handling
equipment
• Industrial
robots
• Pick and place
devices
• ...
• Fork stackers
Assembly
equipment
Monitoring
equipment
• Screwdrivers
• Optical sensors
• Riveting
devices
• Inductive
tracers
• Presses
• ...
• Wrenches
• ...
• ...
Page
Seite 37
Annotations:
Page 37
Lecture 06
The significance of the manufacturing resource Personnel for
Manufacturing and Assembly
Manufacturing
Assembly
Flexible
manufacturing
system
?
Machining
centre
Flexible
assembly
system
NC turning
machine
Handling device
Manual turning
machine
Manual assembly
• Potential of rationalisation exhausted to the
greatest extent possible due to automation
• Potential of rationalisation not completely
exhausted by automation
• Very large volume of manual assembly
Page
Seite 38
Annotations:
While in the field of manufacturing the personnel employment could be reduced, there is still some potential
of rationalization in the field of assembly. Therefore, the manufacturing resource Personnel is of great
importance for the assembly.
Page 38
Lecture 06
Final statement:
The assembly and manufacturing contribute the highest creation of value in the line of
production and because of that they are critical.
The manufacturing can be divided in three basic principles:
Site installation (frequent exchanges of parts and few lots), batch production (consistent
process combinations and many proliferations options), line production (constant operation
sequences and many lots). If it`s necessary, these basic principles can be mixed.
You can differ between four kinds of manufacturing depending on the frequency and the
average batches of the products: Single batch, small batch, high volume and mass
production.
These different kinds of manufacturing require different manufacturing configurations. The
appliance of the principles of manufacturing leads to manufacturing concepts which are
adapted to the kind of manufacturing.
The planning of the manufacturing is divided into three steps:
Describing the task, determination of the technology demand and designing the production.
In order to increase productivity you may consider the opportunity of part families.
Unlike the manufacturing the deterministic planning of the assembly is very complex, so
you have to guess the productions times.
Very complex products are assembled in small batches and mainly require highly skilled
employees. Assembling single and small batches, you often use all-purpose tools.
If you have an easy assembly and high volumes you try to atomize the process for
technical and economic reasons. Thereby more and more atomized tools with a
specialized configuration are utilized.
Four steps are necessary to plan the assembly: Definition of the task, determination of the
assembly structure, determination of assembly scopes and designing the assembly.
There are four types of assembly organizations: site installation, group installation, line
assembly, combined continuous flow assembly.
Still today, the parameter employee has a huge impact in the assembly.
Page 39
Lecture 06
Questions:
• What are the functions of assembly/ manufacturing?
• What are the basic principles of manufacturing? What are there characteristics?
• What principles of manufacturing do you apply considering the circumstances?
• Which steps have to be thought through designing the manufacturing?
• What has to be regarded describing the task?
• Which organizational event can be taken in order to increase productivity? Which
capabilities can be raised?
• What are the steps of atomization in manufacturing?
• Which function does the assembly have?
• Which steps have to be thought through designing the assembly?
• What is the most important parameter to surround the subassembly?
• What are the advantages and disadvantages of the subassembly?
• Why do you try to surround the subassembly?
• What is the foundation of a „good“ manufacturing structure?
• What types of organizations are possible in the assembly? How can they be classified?
Refer the principles to the type of organization!
• What kinds of resources can be used in the assembly?
• Which capabilities are to be raised in assembly?
Page 40
Lecture 06
Bibliography
Manufacturing
a)
Books
Briel, Ralf von: Ein skalierbares Modell zur Bewertung der Wirtschaftlichkeit von
Anpassungsinvestitionen in ergebnisverantwortlichen
Fertigungssystemen, Jost-Jetter, Verlag, 2002
Dangelmaier, W.: Fertigungsplanung, Springer-Verlag, Berlin 1999
Dietrich, A.: Featureintegrierte Fertigungsplanung, Dissertation, Berlin 1996
Eversheim, W: Organisation in der Produktionstechnik, Bd. 4, VDI-Verlag,
Düsseldorf 1989
Eversheim, W.; Schuh, G.: Betriebshütte, Produktion und Management, SpringerVerlag, 1996
Garside, J.: Kosten senken durch modulare Fertigung und optimierte Schnittstellen:
Werkzeuge - Arbeitsblätter – Checklisten, Verlag Moderne Industrie, 2000
Grob, R.: Flexibilität in der Fertigung, Springer-Verlag, Berlin 1986
Jacobs, H-J: Entwicklung und Gestaltung von Fertigungsprozessen, Hanser, 2002
Kistner, K-P: Produktionsplanung, 2001
Sossna, F.: Reorganisation Gruppentechnologischer Fertigungsstrukturen, Shaker
Verlag, 2000
Sonnenschein, K: Feinplanung in felxiblen Fertigungssystemen, Shaker-Verlag,
1998
Teunis, Gerrit: Engpassorientierte Werkstattsteuerung für teilautonome, kooperative
Fertigung Hannover 2003
Neuhausen, Jörn: Methodik zur Gestaltung modularer Produktionssysteme für
Unternehmen der Serienproduktion, 2002
Dohms, Ralf: Methodik zur Bewertung und Gestaltung wandlungsfähiger,
dezentraler Produktionsstrukturen, 2001
Page 41
Lecture 06
b) Journals
Eversheim, W.: Autonome Produktionszellen, Lehrstuhl für Produktionssystematik
am WZL, RWTH Aachen, 2003
Eversheim, W.: Neuartige Fabrikkonzepte sichern Wettbewerbsfähigkeit,
Industrieanzeiger 04, 2001
Gausemeier, J.: Planung der Produkte und Fertigungssysteme für die Märkte von
morgen, VDMA Verlag, 2004
Klocke, F.: Modulare Fertigungsplanung, Lehrstuhl für Technologie der
Fertigungsverfahren am WZL, RWTH Aachen, 1999
Schmidt, K.: Flexible Fertigung, Zohm, F., VDI-Z 09, 1999
Schuh, G.: Strategische Produkt- und Prozessplanung, Lehrstuhl für
Produktionssystematik am WZL, RWTH, Aachen, 2004
Schuh, G.; Gottschalk, S.: Skalierbare Produktionslinien, ZWF 09, 2004
Zohm, F.; Keiser, R: Flexible Fertigung, VDI-Z 09, 2000
Zohm, F.; Bergholz, M.: Die Fabrik im 21. Jahrhundert, RWTH Themen 01, 2002
Zohm, F.; Bergholz, M.; Lange-Stalinski, T.: Die Fabrik von morgen,
Industrieanzeiger 06, 2002
Page 42
Lecture 06
Assembly
a)
Books
Cuiper, Ralf: Durchgängige rechnergestützte Planung und Steuerung von automatisierten
Montagevorgängen, Herbert Utz Verlag, 2000
Esser, H.: Integration von Produktionslogistik und Montageplanung und –steuerung,
Dissertation, RWTH Aachen 1996
Eversheim, W: Organisation in der Produktionstechnik, Bd. 4, VDI-Verlag, Düsseldorf
1989
Eversheim, W.; Schuh, G.: Betriebshütte, Produktion und Management, Springer-Verlag,
1996
Holle, Wolfgang: Rechnerunterstützte Montageplanung, 2002
Jonas, Christian: Konzept einer durchgängigen, rechnergestützten Planung von
Montageanlagen, Herbert Utz Verlag, 2000
Kratzsch, Sabine: Prozess- und Arbeitsorganisation in Fließmontagesystemen, VulkanVerlag, 2000
Westkämper, H-J: Montageplanung :effizient und marktgerecht, Springer Verlag, 2001
b) Journals
Eversheim, W.: Ganzheitliche Neugestaltung der Werkzeugmaschinenmontage, Lehrstuhl
für Produktionssystematik am WZL, RWTH Aachen, 1999
Eversheim, W.; Schuh, G.: Global Footprint, CIRP General Assy Antalya 08 2005
König, Roland: Optimierung der Fertigung und Montage für die
Werkzeugmaschinenproduktion, ZERBST Werkzeugmaschinenfabrik
GmbH, 2004
Meyer, M.;Lücke,T.: Lean Supply Chain, WT Online 04, 2004
Schuh, G.; Desoi, J.C; Tücks, G.: Optimized Production Ramp-up in Automotive
Industry,IDDME Bath 04 2004
Schuh, G.; Kampker, A.; Ripp, S: Smart Logistics, WT Online 04, 2005
Page 43

Laboratory for Machine Tools and Production Engineering

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