Abstract
Current trend in automotive industry shows increasing demand for multiple models with lean production. Prior to that, automotive manufacturing systems evolved from mass production to flexible automation. Material handling systems and equipment in a single assembly line with multiple models require high investment but with low throughput thus making production cost relatively high. Current assembly process of side structure and undercarriage with downtime occurrence during assembly process affecting production performance (quality, cost and delivery). Manufacturing facilities should allow more flexibility and increase intelligence evolving toward novel reconfigurable assembly systems (RAS). RAS is envisaged capable of increasing factor flexibility and responsiveness by incorporating assembly jig, robot and framing, which could be next generation of world class automotive assembly systems. This project research proposes a new methodology of framework reconfigurable assembly systems principles in automotive framing systems i.e. enhance assembly process between side structure assembly and undercarriage assembly which a new RAS is capable to reconfigure the assembly processes of multiple model on a single assembly line. Simulation software (Witness) will be used to simulate and validate current and proposed assembly process. RAS is expected to be a solution for rapid change in structure and for a responsively adjustable production capacity. Quality, cost and delivery are production key parameters that can be achieved by implementing RAS.
Highlights
Current global economy scenario shows new enablers are needed in both product development and manufacturing systems due to open and unpredictable market changes
Based on Organisation Internationale des Constructuers d’ Automobiles or The International Organization of Motor Vehicle Manufacturers (OICA), automotive manufacturer which Total Industry Volume (TIV) for passenger cars production annually less than 200,000 units can be categorized as small automotive industry [1]
This paper focus on the manufacturing systems by identifying various potential flexible elements for product platform design and identify their physical interaction with manufacturing mainbody framing systems
Summary
Current global economy scenario shows new enablers are needed in both product development and manufacturing systems due to open and unpredictable market changes. Produce multiple models in a single line and an integration between material handling and equipment. To overcome these problems new trends evolution of automotive framing systems should be considered. In the final assembly, most of major automakers are building more models, gained from global platforms, on the production lines that can simultaneously handle multiple products allowing for efficient utilization of people and equipment. The hypothesis is that if the correct subsets of automotive body segments and production capabilities are designed considering for future flexibility based on the reconfigurability principles, the manufacturing system can better adapt body styling changes, variants of family production without the need for tooling changeover with significant increase in throughputs
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