Abstract
The purpose of this paper is to propose a novel process failure mode and effect analysis (PFMEA) approach for the reliable design of assembly activities to prevent product defects due to errors during the assembly of complex products. PFMEA is approached as an integrated method that, in addition to implementing recommended actions, supports the design of worksheets, equipment, and layout of the assembly lines of complex systems, early in the design phase of the product. As a result, the innovative design-job element sheets (D-JESs), which report work instructions to the operator for assembly cycles, are defined before the design of the production and assembly process. The modification of the PFMEA structure, the implementation of proper recommended actions, and the designs of D-JESs, equipment, and assembly layout, early in the design phase of the product, are the novel contributions of the paper. The integrated method assures to effectively design the assembly process directly during the product design to avoid errors that could promote dissatisfaction of the end-users. It is practical to use and does not require large investments, implementation of new technologies, or complex additional training. Its practical application is demonstrated using a case study concerning a manufacturer of train wagons via manual assembly lines.
Highlights
The philosophy of build-in reliability (BIR) is widely adopted by current manufacturing industries, as customers demand greater reliability for all products [1]
The purpose of this paper is to propose a novel process failure mode and effect analysis (PFMEA) approach for the reliable design of assembly activities to prevent product defects due to errors during the assembly of complex products
PFMEA is approached as an operative tool able to bridge the gap between design information and industrialization activities to support the design of the design-job element sheets (D-job element sheet (JES)), equipment, and assembly line layout for complex systems
Summary
The philosophy of build-in reliability (BIR) is widely adopted by current manufacturing industries, as customers demand greater reliability for all products [1]. The BIR principles are used during the early stages of product development (i.e., design and industrialization) to ensure that both wear-out and special failure mechanisms are eliminated (or strongly reduced and controlled) from the useful life of the product. BIR describes the entire set of tools that support product and process design to ensure that customer’s expectations for reliability are fully satisfied throughout the whole life of the product. BIR process encompasses a variety of tools and practices and describes the overall order of deployment that an organization needs to follow to design reliability into its products. In reference [2], Mettas presents an interesting discussion concerning tools and techniques in support of product reliability improvement breaking down the BIR (or design for reliability, DFR) process into six key activities, which are: define, identify, analyze and assess, quantify and improve, validate and monitor, and control. Understanding when, what, and where to use the wide variety of the available reliability engineering tools will help to achieve the reliability mission of an organization
Sign-in/Register to view highlights & summary 
Published Version (
Free)
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call