Abstract
This research aims to gain a detailed understanding of data producers, data consumers and format/flow of the data within automotive industry for defining and using Bill of Process (BoP) for engine assembly lines. The focus remained on the real industrial challenge of rapid constraint evaluation for designing and/or reconfiguration of Powertrain assembly lines to cater for a new/changed product. A methodology is developed to facilitate Ford Company to quickly model and re-configure new/changed assembly line for building new/changed engine. This is made possible with the help of modular approach and developing relationships among products, processes and resources. The data and information of the PPR is made available to all the stake holders of the organisation independent of the platform or specific application being used at the department/facility.
Highlights
The recent advancements in the information and telecommunications have made possible global alliances among enterprises while changing customer needs are characterised by a rapidly emerging global market economy
Approximately 70% of the assembly line machines remain the same, only 30% of machines / modules are required to be built for the changed product
Definitions, characteristics and classification of a generic Bill of Process (BoP) would help process engineers to quickly build the machines in virtual environment and test and de-bug if required
Summary
The recent advancements in the information and telecommunications have made possible global alliances among enterprises while changing customer needs are characterised by a rapidly emerging global market economy. Products entering into the markets are designed and manufactured across geographical boundaries, distributed and marketed worldwide. In addition to the worldwide challenge, the companies are facing many challenges such as shorter time to market, improved process yield, non-stop operations, tighter supply couplings, newer and innovative technologies, complexities in products and larger/virtual organisations. Product Lifecycle Management (PLM) system is a sequence of steps including product design and development process that enterprises employ to conceive design and commercialise the product. The manufacturing efficiency and competitive advantage can be improved when enterprises capitalising on an entire product lifecycle chain to bring real time shop floor visibility across the enterprise. Faster time to market can be achieved when manufacturing requirements are synchronised with the product design and geographically
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