Abstract
The proposed work aims to acquire the maximum number of non-linear assemblies with closer assembly tolerance specifications by mating the different bins’ components. Before that, the components are classified based on the range of tolerance values and grouped into different bins. Further, the manufacturing process of the components is selected from the given and known alternative processes. It is incredibly tedious to obtain the best combinations of bins and the best process together. Hence, a novel approach using the combination of the univariate search method and the harmony search algorithm is proposed in this work. Overrunning clutch assembly is taken as an example. The components of overrunning clutch assembly are manufactured with a wide tolerance value using the best process selected from the given alternatives by the univariate search method. Further, the manufactured components are grouped into three to nine bins. A combination of the best bins is obtained for the various assembly specifications by implementing the harmony search algorithm. The efficacy of the proposed method is demonstrated by showing 24.9% of cost-savings while making overrunning clutch assembly compared with the existing method. The efficacy of the proposed method is demonstrated by showing 24.9% of cost-savings while making overrunning clutch assembly compared with the existing method. The results show that the contribution of the proposed novel methodology is legitimate in solving selective assembly problems.
Highlights
Product quality is the focus of any manufacturing process
It is un17doefr2s0tood that while increasing the partition number, there may be a 5.8% (938 assemblies) dro17poifn2p0 roducing the number of assemblies for the same assembly specification
This paper addresses a novel methodology by combining the univariate search method and the harmony search algorithm in selective assembly for making non-linear assemblies for various assembly specifications
Summary
Product quality is the focus of any manufacturing process. In general, two or more components are assembled to create an assembly. Tolerance plays an essential role in the component’s quality, deciding the fit between the mating parts. The components manufactured with closer tolerance make the precise assembly more suitable for functional requirements. Selective assembly is one of the feasible methods for making precise assemblies with lower manufacturing costs. The complete elimination or reduction of secondary operations by forming wide-tolerance components is the reason for lower manufacturing costs. According to the best bin combinations, the precise assemblies are made by mating the components randomly selected from the corresponding bins. In the existing literature, the tolerance of the components is usually considered for obtaining the best bin combinations rather than the dimension of components. Selection of process for making components from the given alternative processes plays a vital role in further reducing the product’s manufacturing cost
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