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Produktionsmanagement I (Prof. Schuh) Lecture 06 Planning and Organisation for Manufacturing and Assembly L06 Page 1 © WZL/Fraunhofer IPT Production Management I - Lecture 6 - Planning and Organisation for Manufacturing and Assembly Contact: Dipl.-Ing. D. Kupke [email protected] WZL 53B R515 Tel.: 80 - 28210

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Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 1

© WZL/Fraunhofer IPT

Production Management I- Lecture 6 -

Planning and Organisation for Manufacturing and Assembly

Contact:Dipl.-Ing. D. [email protected] 53B R515Tel.: 80 - 28210

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 2

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

Characteristica and problems of assembly L6 Page 23

Tasks of assembly planning L6 Page 26

Definition of assembly tasks L6 Page 27

Determinaton 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

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 3

AbstractThe 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 sec-tor 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, personell, material to be processed

• Erläutern der Hilfsmittel zur Planung der Fertigung und Montage

In addition to that the furture 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 datat,

- sub-assembly,

- main-assembly,

- assembly organisation forms,

- forms of material provision

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 4

Glossary

Manufacturing concept: Logical and spacial arrangement of productionmeans and work stations; divided into job shop, group and continous flow manufacturing.

Assembly concept: Logical and spacial arrangement of the assemblywork stations; divided into site installation, group-, line-, time-phased production line and continousflow assembly.

Job shop manufacturing: Arrangement of production means and workstations according to the manufacturing method(methods of the same kind are centralised into one„competence centre“); suitable for frequentlychanging workpieces and small scale production.

Group manufacturing: Arrangement of production means and workstations according to the product (all methodsneeded to machine a group of workpieces arelogically and spacially combined); suitable forrecurrent manufacturing methods with frequentlychanging variants.

Continous flow manufacturing: Arrangement of production means and workstations according to the sequence of themanufacturing processes of a workpiece (flowprinciple); suitable for recurrent/ similarmanufacturing processes and large scaleproduction.

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 specificvariants are possible (e.g. automotive industry).

Performance production arrangement: Form of assembly organisation with stationaryassembly objects (Site installation or Group assembly).

Continous flow arrangement: Form of assembly organisation with movingassembly objects (Line assembly, Time-phasedproduction line assembly or Continous flowassembly).

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 5

© WZL/Fraunhofer IPT Page 5

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

Assembly organisation forms

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 6

© WZL/Fraunhofer IPT Page 6

Planning of Manufacturing and Assembly

Business management / Controlling

Purchasing Design Operations planning

Manu-facturing

Assembly Sales

Types of organisation Planning of facilities/ production means

Trends

1999 2001 2003[Year]

?

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 7

© WZL/Fraunhofer IPT Page 7

Effects of Manufacturing and Assembly on Preceding Areas of Production

Modification of machining

procedures

Design Drawing up of manufacturing

documents

Operations planningOperations planning

Operations management

ManufacturingManufacturing of

single parts

AssemblyAssembly of single parts and modules

Manufacturing process

Products

Machining possibilities

Design modifications

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 processsequence.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 8

© WZL/Fraunhofer IPT Page 8

The significance of the divisions Manufacturing and AssemblyNet added value [%]

Purchasing Design Operationsplanning

Manu-facturing Assembly Sales

10095

65

35

25

5

Supplier A

Supplier B

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 9

© WZL/Fraunhofer IPT Page 9

Functions and Equipment of Manufacturing

Provision of information

Staging of workpiece

Buffering of workpiece Tool change

Functions

Workpiecechange Machining Process

monitoring

Measuring, checking

Removal of chips

Manufacturing equipment

F

Manufacturing System

Machine Tools Tools Fixtures

Annotations:

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 10

© WZL/Fraunhofer IPT Page 10

Comparison of different Manufacturing PrinciplesGroup manufacturingJob shop

manufacturing Continuous flow manufacturing

Typical arrangement

Machining cellMachine shop Line of machines

Structure of the manufacturing sector

Raw materials stockRaw materials stock Raw materials stock

Finished-parts store Finished-parts store

Criteria of structure:Criteria of structure: Criteria of structure:Combination of the necessary

machining procedures forone family of workpiece

Combination of the same type of machine tools

Operation sequence of onefamily of parts determines

the flow line

D

D

F

F

D

D

F

F

B

B

B D

F

B

F

B

S

F

D

F

D

SS

F

B

B

D

B

F

S F

D

B

Finished-parts store

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 ororganisation-related. Besides the basic manufacturing principles, hybrid forms can be generated.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 11

© WZL/Fraunhofer IPT Page 11

Suitability of different Manufacturing Principles

Continuous flow manufacturing

Legend: - Low suitability - Limited suitability - Good suitability

a

a

a

a

a

a

a

a

a

a

a

a

a

Ab

Criteria of machining Principles of manufacturingJob shop

manufacturing Group

manufacturing

Similarity of form

Sameness of form

Technological similarity

Uniformity of processes per workpiece

Correspondence of range of dimension

Complexity of process per workpiece

Great differences in processing times

High lot frequencies

Big number of processes per workpiece

Big quantity of items per lot

Uniformity of process sequences per workpiece

Great demands on work contents

Great demands on allocation of costs

Great demands on control and schedule monitoring

Org

anis

atio

nPr

oced

ure

Wor

kpie

ce

Annotations:

Suitability of manufacturing principles against the background of certain criteria of evaluation.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 12

© WZL/Fraunhofer IPT Page 12

Kinds of Production

Frequency of repetition =Average lot size

Year

Freq

uenc

yof

repe

titio

n

Produced annual quantity of items

10 4

10 3

10 2

10 1

1

10 -1

10 5

10 410 310 210 11 10 -1 10 5 10 810 710 6 10 9

Mass production

Large-batchproduction

Example: Electronichardware manufacturers

Example: Home appliance manufacturers

Example: Machine tool manufacturers

Example: Plant construction

Individual production

Small-scale production

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 13

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Characteristics of Small Scale and Large Scale Production

Individual and small scale production

Large scale and mass production

Order data

Manufacturing equipment

Manufacturing process

Changeover of manufacturing

Proportion of operating time

Capacity utilisation

Space utilisation

Proportion of side operation time

Proportion of changeover time

frequently

low

small

low

big

average

Lot size small big

rarely

big

Annual quantity of items small big

big

high

small

small

Annotations:

Individual and small scale production and large scale and mass production differ in:

• order data

• manufacturing equipment

• manufacturing process

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 14

© WZL/Fraunhofer IPT Page 14

Fields of application of different Manufacturing Concepts

Non-interlinked NC-

manufacturing

Manufacturing cell Machining

centre Flexible manufacturing

system Flexible manufacturing

lineTransfer line

Quantity of items per variant

Num

ber o

f var

iant

sField of application:- minimum quantities of items- little similarity of parts Field of application:

- frequent order change- little similarity of parts

Field of application:- frequent order changes- small quantities of items

Field of application:- large-batch and mass

production- rare order change

Field of application:- average quantities of items- complex machining task

Field of application:- average or big quantities of items- great similarity of parts

Example: Aircraft construction

Example: Tool manufacturing

Example: Prototypemanufacture

Example: Housing manufacturing Example: Engine manufacturing Example: Automotive industry

Annotations:

Comparison between number of variants/ quantity of items per variant and corresponding fields of application.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 15

© WZL/Fraunhofer IPT Page 15

Manufacturing Planning

Manufacturing planning

Description of machining taskDescription of machining task by means of geometric,

technical and order-related parameters

Derivation of technology requirementsaccording to types and characteristics of

necessary manufacturing equipment

Disposition of manufacturing sectorDetermination of capacity requirements and of thearrangement structure of manufacturing equipment

Analysis of product• product structure• order data• criteria of selection

Analysis of potential• performance data• degree of automation• add-ons

Analysis of potential• principles of manufacturing• conveyance frequency• priority rules

Acc

ompa

nyin

g ev

alua

tion

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 16

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Essential parts belonging to aComprehensive Description of a Machining Task

Machining taskMaterial: CK 45 Elementary form:

Forging blank

Derived machine requirements

• Precisions/ procedure

• Speed graduations

• Performance

• Rates of feed

Organisational data

• Parts families• Quantities of items• Number of variants• Lot size/ frequency of

repetition

Technological data

• Material/hardness/machining property

• Tolerance requirements

• Heat treatment

• Pre-machining/ finemachining

Geometry of moulded elements

• Bends/ radii

• Tolerances

• Bevellings/ legs of trajectory

• Discontinuities ofdiameters

Geometry of workpiece

• Size• Type and quantity of

moulded elements• Type of external form

(e.g. uphill casted on oneside)

• Rotational part with/without deviations

Gear tooth forming

Cone

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 17

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Manufacturing of part families

Form Dimension

Geometric similaritywith regard to:

Technological similaritywith regard to:

Chucking means Machining Measuring means

Manufacturing of part families

Workpiece system

Classification system

Higher productivity

Rationalisation of design

Adapted production

means

Higher degree of automation

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 18

© WZL/Fraunhofer IPT Page 18

Overview: Processing Requirements – Machine RequirementsAnalysis of workpiece

Organisational data

Technological data Geometry of workpiece

Derived machine requirements

Processing requirements overview

Maximum workpiece lengthMaximum workpiece diameter

Maximum machine accuracy

Machine requirements overview

Balancing

Geometry of moulded elements

Maximum machine-tool output

Annotations:

The machine has to meet the requirements that are necessary to carry out the machining task.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 19

© WZL/Fraunhofer IPT Page 19

Selection of a suitable Type of ManufacturingRequirements Profile of

Batch Production

Non-interlinked NC-machines

Manufac-turing island

Machining centre

Flexible manufacturing

system

Transfer line

Flexible manufacturing

line

Short throughput time

High productivity

Low investment

Little manpower

requirements

High flexibility

High quality

Performance profile of manufacturing types

Legend:

Requirements profile

Performance profile

Deficiencies

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 20

© WZL/Fraunhofer IPT Page 20

Derivation of the Machine Plan

Analysis ofparts spectrum

Determination of operation

sequence

Calculation ofcapacity

requirements

Calculation ofnumber of machines

• Quantity of items

• Machining requirements

• Alternative operationsequences

• Clearing-up Capacity balancing

Number of machinesCapacity balancingStandard operation

sequence

Representativeworkpiecespectrum

12 13

131 132Necessary capacity

requirements

Capacity availability per

machineTurn

ing

Dril

ling

Mill

ing

h/a

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“.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 21

© WZL/Fraunhofer IPT Page 21

Results of the Lecture Part Manufacturing

Functions of manu-facturing equipment

Planning phases of manufacturing

Trends: ?

Principles of manufacturing

Manufacturing types

Derivation of a machine plan

Business management / Controlling

Purchasing Design Operations planning

Manu-facturing

Assembly Sales

Overview processing requirements vs.

machine requirements

Annotations:

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 22

© WZL/Fraunhofer IPT Page 22

Automation levels of manufacturing

Aut

omat

ion

leve

ls

3

2

1

4

NC-control

Starting point: Conventional production facilities Increasing integration

Information flow controlMaterial flow controlMeasuring systemMonitoring system

Workpiece changing systemTool changing systemWarehouse system

Workpiece conveyance systemTool conveyance systemDisposal system

Company objectives

• Throughput time reduction

• Increase of production quality

• Reduction of personnel costs

• Increase of system transparency• Increase of flexibility• Reduction of

changeover times

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 23

© WZL/Fraunhofer IPT Page 23

Problems of Planning and Controlling the Assembly Compared with Machining by Stock Removal

Manufacturing Assembly

Planning and control task

For the most part clear operation sequence

sawing turning milling

• Average value tables

• Company-specificguideline values

• Standard time files

• Raw part• Personnel

Information• Production

meansSingle part

Operation sequence

Determination of time

Coordination

Networked operationsequence

• Comparison• Estimation• Calculation of

relevant factors• Time

• Single part• Module• Personnel

Information• Production means • Area

Product

Raw parts Finished parts

Zeit

E

Finished parts ProductAssemble

Assemble Finished parts

Finished parts

Assemble

Annotations:

In the following, manufacturing and assembly will be contrasted:

The assembly process is networked by the material that is brought together; the necessarymotion sequence is often complicated.

The deterministic planning is usually very complex; e. g. the determination of times has to beestimated.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 24

© WZL/Fraunhofer IPT Page 24

Functions of the Assembly System

InputSingle parts

Modules

OutputProductsMain

function

Secondary functions

M A

Assembling Storing Conveying

HandlingAdjusting

Controlling

According to: Eisenmann

According to: Kuka

According to: MahoAccording to: Renk According to: Gildemeister

According to: DEXION

Assembly process

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 fixturesspecially adjusted to individual products are used.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 25

© WZL/Fraunhofer IPT Page 25

Characteristics and problems of assembly with different Production Conditions

Individual and small scale assembly

Large scale assembly

Parameters of assembly

External feature

Typical problems

Almost exclusively manual assembly

- long throughput times- many missing parts- Capacity constraints- regarding: Personnel

AreaTest benches

- longer breakdown and side operation times due to:

- conveyance works- adaptation works

Multiplicity of parts High Low

Increasing mechanisation and automation of processes

- time-consuming planning of procedure in case of

- modifications of production conditions

- design modifications or newproducts

- material planning problemsconcerning staging

- in case of station failure consi-derable effects on the productivity

Parts geometry Variable ConstantLot sizes Small Very bigDependencies on customer requests High LowWork instruction Rough DetailedMaterial flow Discontinuously ContinuouslyMaterial to be processed Dependent on order Program-oriented

Annotations:

Highly complex products are usually manufactured in small lot sizes. Their production demandsfor qualified personnel.

For easier assembly tasks and large lot sizes the automation of the assembly processes isdesirable from both the technical and the economical point of view.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 26

© WZL/Fraunhofer IPT Page 26

Tasks of Assembly PlanningRequirements for planning the assembly

Room Energy Information Constraints AimsSalesMarket shareCosts

Definition ofassembly tasks

Determination ofassembly structure

Determinationof assembly

Determination of

Product data Production data

Determination oforganisationform

- final assembly - module

assembly-

- pre-assembly- main assembly- subsequent

assembly-

- weight- dimensions - assembly - operation

sequence

- product variants- quantity of items

- Site installation - Group assembly - Planning of production means- Planning of personnel- Determination of assembly process

Disposition of assembly

assembly levels assembly phases

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 beexplained in detail in the follöowing.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 27

© WZL/Fraunhofer IPT Page 27

Data for the characterisation of an Assembly Task

Production-related data

Product-related data

Products to be assembled

P1 P2 P3 P4 P5 P6 P7

Product capacity profile

- Number of different products

- Gradients of quantity of items

- Production times

- Logical interdependency of assembly activities

- Capacity requirements- Variant-specific capacity shares

- Single parts- Weight

Quantity of items

Time

Time

Capacity requirements

Annotations:

Description of the assembly task by means of:

• production related data,

• capacity profile,

• product related data.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 28

© WZL/Fraunhofer IPT Page 28

Subdivision into sub-assembly and main assembly

Legend: SA: sub-assemblyMA: main assembly

Initial information Constraints

Centralised Organisational

Decentralised

Single-stage

Multi-stage

Product structure

Subdivision into

sub-assembly and

main assembly

- Quantity of items- Variant code- Lot sizes

- Technique- Technology- Separation of manual and

automatic sectorsOrganisational

- Order-oriented- Programme-oriented- Consumption-orientedSub-assembly A

Line 1

Line 2

Sub-assembly A

Sub-assembly B

SA 2SA 1

MA

MASA1SA2SA3

Annotations:

Thje single most important influencing factor for the delimitation of the sub-assembly areas is theproduct 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

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 29

© WZL/Fraunhofer IPT Page 29

Aims of separating Sub-Assembly Areas from Main Assembly Areas

Examples ExamplesAims

Variant-independent SA

variant-dependent MA

- Reduction of throughput time

- Decoupling of subsystems- Concentration of variant effect

- Simplification of automation possibilities in subsystems

- Interlinking equipmentmatched for basic components

- Good accessibility to assembly object in pre-assembly areas

- Possibility to shift assembly volumes to suppliers

Legend: SA = sub-assemblyMA = main assembly

SABuffer

MA

Manual sub-assembly

Automatic main assembly

Saving of throughput time

SAMA

t

SA

MA

MAStaging of bought-inmodules

Annotations:

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 30

© WZL/Fraunhofer IPT Page 30

Coherency between Product Structure and Assembly StructureEfficient determination of product structure

Product structure Assembly structure

Final assembly

Sub-assembl

y

Intermediate store

Sub-assembl

y

Sub-assembl

y

A CB

Warehouse

Which part

is assembled

When

Where

How

With whom

By whom

Product

UNUN

CPCP CP CP CP

SA SA SA

SP

SP

SP

SP

SP

SA

Legend: UNCPSASP

= Unit= Component= Subassembly= Single part

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.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 31

© WZL/Fraunhofer IPT Page 31

Kinematic Alternatives of Organisational Forms in Assembly

Assembly organisation forms

Continuous flow arrangementPerformance production arrangement

Stationary assembly objects

Fließprinzip

Moving assembly objects Moving assemblyobjects

Stationary workstations

Moving workstations Stationary work stations Moving work

stations

Site installation

Group assembly

Line assembly Time-phased production line

assembly

Continuous flow

assembly

Mov

e ch

arac

teris

tics

Adv

anta

ges

and

disa

dvan

tage

s +Good feasibility of special orders

+...- Extended capital

tie- up- ...

+Modest arearequirements

+...-High control costs- ...

+ Low qualification standards+ ...- High planning costs- ...

+Great transparencyof assembly process

+...- Low suitability for

special orders- ...

Legend: -mechanical assembly equipment

-manual work station

- assembly object - object move - work station move

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

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 32

© WZL/Fraunhofer IPT Page 32

Types of production means in the Assembly Department

Types of production means in the assembly department

• Roller conveyors

• Chain conveyors

• Monorails• Fork stackers• ...

• Warehouse• Bunker• Hoppers• Shelves

• Industrial robots

• Pick and placedevices

• ...

• Screwdrivers• Riveting devices

• Presses• Wrenches• ...

• Optical sensors• Inductivetracers

• ...

Conveyance equipment

Storageequipment

Handling equipment

Assemblyequipment

Monitoringequipment

Annotations:

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 33

© WZL/Fraunhofer IPT Page 33

The significance of the manufacturing resource Personnel for Manufacturing and Assembly

Manufacturing 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

Flexible manufacturing

system

Machining centre

NC turning machine

Manual turning machine

Flexible assembly system

Handling device

Manual assembly

?

Annotations:

While in the field of manufacturing the personnel employment could be reduced, there is still some potential of rationalisation in the field of assembly. Therefore, the manufacturing resourcePersonnel is of great importance for the assembly.

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 34

Bibliography

Manufacturinga) 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. Betriebshütte, Produktion und Management Schuh, G. Springer-Verlag, 1996

Garside, J. Kosten senken durch modulare Fertigung und optimierte Schnittstellen: Werkzeuge - Arbeitsblätter – ChecklistenVerlag Moderne Industrie, 2000

Grob, R. Flexibilität in der Fertigung,Springer-Verlag, Berlin 1986

Jacobs, H-J Entwicklung und Gestaltung von FertigungsprozessenHanser, 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 Fertigungen,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

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 35

b) Journals

Eversheim, W. Autonome ProduktionszellenLehrstuhl für Produktionssystematik am WZL, RWTH Aachen, 2003

Eversheim, W. Neuartige Fabrikkonzepte sichern WettbewerbsfähigkeitIndustrieanzeiger 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 FertigungZohm, F. VDI-Z 09, 1999

Schuh, G. Strategische Produkt- und Prozessplanung,Lehrstuhl für Produktionssystematik am WZL, RWTH Aachen, 2004

Schuh, G. Skalierbare ProduktionslinienGottschalk, S. ZWF 09, 2004

Zohm, F. Flexible FertigungKeiser, R. VDI-Z 09, 2000

Zohm, F. Die Fabrik im 21. JahrhundertBergholz, M. RWTH Themen 01, 2002

Zohm, F. Die Fabrik von morgenBergholz, M. Industrieanzeiger 06, 2002Lange-Stalinski, T

Produktionsmanagement I (Prof. Schuh) Lecture 06

Planning and Organisation for Manufacturing and Assembly L06 Page 36

Assemblya) Books

Cuiper, Ralf Durchgängige rechnergestützte Planung und Steuerung von automatisierten Montagevorgängen,Herbert Utz Verlag, 2000

Esser, H. Integration von Produktionslogistik und Montage-planung und –steuerung,Dissertation, RWTH Aachen 1996

Eversheim, W Organisation in der Produktionstechnik,Bd. 4, VDI-Verlag, Düsseldorf 1989

Eversheim, W. Betriebshütte, Produktion und Management,Schuh, G. 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,Vulkan-Verlag, 2000

Westkämper, H-J Montageplanung :effizient und marktgerecht,Springer Verlag, 2001

b) Journals

Eversheim, W. Ganzheitliche Neugestaltung der WerkzeugmaschinenmontageLehrstuhl für Produktionssystematik am WZL, RWTH Aachen, 1999

Eversheim, W. Global Footprint,Schuh, G. CIRP General Assy Antalya 08 2005

König, Roland Optimierung der Fertigung und Montage für die Werkzeugmaschinenproduktion,ZERBST Werkzeugmaschinenfabrik GmbH, 2004

Meyer, M. Lean Supply Chain,Lücke, T. WT Online 04, 2004

Schuh, G. Optimized Production Ramp-up in Automotive Industry,Desoi, J. C. IDDME Bath 04 2004Tücks, G.

Schuh, G. Smart Logistics,Kampker, A. WT Online 04, 2005Ripp, S.