Towards 100% Overall Equipment Effectiveness (OEE) at Semi-automatic Assembly Lines – Case Study

2021 ◽  
pp. 281-289
Author(s):  
Péter Dobra
Keyword(s):  
Automatic Assembly ◽  
Assembly Lines

scholarly journals Digital Twin for Designing and Reconfiguring Human–Robot Collaborative Assembly Lines

2021 ◽  
Vol 11 (10) ◽  
pp. 4620
Author(s):  
Niki Kousi ◽  
Christos Gkournelos ◽  
Sotiris Aivaliotis ◽  
Konstantinos Lotsaris ◽  
Angelos Christos Bavelos ◽  
...  
Keyword(s):  
Production System ◽  
Assembly Lines ◽  
Flexible Assembly ◽  
Digital Twin ◽  
Collaborative Assembly ◽  
Geometrical Information ◽  
Line Level ◽  
Dual Arm ◽  
Different Levels

This paper discusses a digital twin-based approach for designing and redesigning flexible assembly systems. The digital twin allows modeling the parameters of the production system at different levels including assembly process, production station, and line level. The approach allows dynamically updating the digital twin in runtime, synthesizing data from multiple 2D–3D sensors in order to have up-to-date information about the actual production process. The model integrates both geometrical information and semantics. The model is used in combination with an artificial intelligence logic in order to derive alternative configurations of the production system. The overall approach is discussed with the help of a case study coming from the automotive industry. The case study introduces a production system integrating humans and autonomous mobile dual arm workers.

scholarly journals Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company

2020 ◽  
Vol 10 (7) ◽  
pp. 2433 ◽  
Author(s):  
Arturo Realyvásquez-Vargas ◽  
Karina Cecilia Arredondo-Soto ◽  
Jorge Luis García-Alcaraz ◽  
Emilio Jiménez Macías
Keyword(s):  
Software Tool ◽  
Assembly Lines ◽  
Customer Complaints ◽  
Industrial Companies ◽  
Manufacturing Company ◽  
Individual Contributions ◽  
Research Goal ◽  
Corrective Actions ◽  
Problem Solving Process

Customer satisfaction is a key element for survival and competitiveness in industrial companies. This paper describes a case study in a manufacturing company that deals with several customer complaints due to defective custom cable assemblies that are integrated in an engine. The goal of this research is to find a solution to this problem, as well as prevent its recurrence by implementing the eight disciplines (8Ds) method in order to: (1) develop a team, (2) describe the problem, (3) develop an interim containment action, (4) determine and verify root causes, (5) develop permanent corrective actions, (6) define and implement corrective actions, (7) prevent recurrences, and (8) recognize and congratulate teamwork as well as individual contributions. Therefore, a software tool is proposed to conduct a functional test on assembly lines. After the test, the problem was successfully reduced and detected, because from 67 engines that were identified with problems, 51 were redesigned before being sent to customers, consequently decreasing the number of defective products by 75%, whereas the remaining 16 engines were replaced by new engines. In conclusion, the research goal was accomplished, and the 8Ds method proved to be a helpful model with which to increase employees’ motivation and involvement during the problem-solving process.

scholarly journals Mixed integer linear programming models for minimizing ergonomic risk dispersion in an assembly line at the Nissan Barcelona factory

2018 ◽  
pp. 72-89 ◽  
Author(s):  
Joaquín Bautista-Valhondo ◽  
Rocío Alfaro-Pozo
Keyword(s):  
Assembly Line ◽  
Mixed Model ◽  
Assembly Line Balancing ◽  
Mixed Integer ◽  
Assembly Lines ◽  
Absolute Deviation ◽  
Mixed Model Assembly Lines ◽  
Average Maximum ◽  
Ergonomic Risk

We present a variant of the approach to the assembly line balancing problems, with the aim of reducing the ergonomic risk for operators of mixed-model assembly lines (MILP-3). Specifically, the MILP-3 model is focused on minimizing the average range between ergonomic risk values of workstations. Using a case study from Nissan’s plant in Barcelona, not only are the differences between levels of ergonomic risk of stations reduced, but we attempt to reduce the average maximum ergonomic risk of the assembly line. The new model is compared with two others, MILP-1 and MILP-2, which minimize the average maximum ergonomic risk and the average absolute deviation of the risks, respectively.

scholarly journals OEE measurement at the automotive semi-automatic assembly lines

2021 ◽  
Author(s):  
Peter Dobra ◽  
János Jósvai
Keyword(s):  
Literature Review ◽  
Automotive Industry ◽  
Performance Indicators ◽  
Key Performance Indicators ◽  
Automatic Assembly ◽  
Manufacturing Companies ◽  
Assembly Lines ◽  
Performance Quality

Manufacturing companies continuously evaluate their achieved performance based on different Key Performance Indicators (KPI). This article gives an overview about the OEE values. The study aims to provide practical OEE data of semi-automatic assembly lines used in the automotive industry. Its novelty is the revealed relationship between seat assembly lines and seat subassembly lines. Firstly, a literature review shows the scientific relevance and several cases are collected to increase OEE percentage. Secondly, the connection between chassis, tracks, recliner and mechanism assembly lines is described. Each part of OEE (availability, performance, quality) are analysed in terms of their impact.

Modeling in Mixed-Model Assembly Lines Based on Object-Oriented Petri Net

2014 ◽  
Vol 945-949 ◽  
pp. 3156-3159
Author(s):  
Hai Dong ◽  
Heng Bao Xin ◽  
Jian Hua Yan
Keyword(s):  
Petri Net ◽  
Mixed Model ◽  
Object Oriented ◽  
Message Delivery ◽  
Assembly Lines ◽  
Mixed Model Assembly Lines ◽  
Definition Of ◽  
Property Verification ◽  
Mixed Model Assembly

In order to model clearly in mixed-model assembly lines, this paper proposes an Object-oriented Petri Net (OOPN) approach by combining object-oriented concept with Petri net theory. Firstly, the mathematical definition of OOPN was given. Secondly, taking automobile transmission mixed-model assembly lines as an example, the modeling through three different levels of assembly cells, assembly resources and the whole system was finished, and the message delivery mechanism and system behavior were then described in detail. Finally, the case study shows that OOPN can deal well with the complexity of modeling, and it lays the foundation of further analysis and property verification in the mixed-model assembly lines.

Overall Task Effectiveness: a new Lean performance indicator in engineer-to-order environment

2019 ◽  
Vol 68 (2) ◽  
pp. 407-422 ◽  
Author(s):  
Marcello Braglia ◽  
Roberto Gabbrielli ◽  
Leonardo Marrazzini
Keyword(s):  
Performance Indicator ◽  
Assembly Lines ◽  
Manual Assembly ◽  
Content Type ◽  
Efficiency And Effectiveness ◽  
Time Standards ◽  
Corrective Actions ◽  
Engineer To Order ◽  
Classification Structure

Purpose The purpose of this paper is to propose a new Lean metric named Overall Task Effectiveness (OTE), which can help analyst to define target task times and to identify the hidden losses that account for most of the recorded time of manual assembly activities. Design/methodology/approach An alternative classification structure of the losses is developed to divide them in two classes. In the first one the losses that are external to the project order are included, and in the other one those due to inefficiencies directly ascribable to the project order are considered. Starting from this classification structure of the losses, a novel Lean metric, inspired from the well-known Overall Equipment Effectiveness (OEE), is developed to evaluate the effectiveness of a manual assembly task. A case study, which briefly explains the methodology and illustrates the capability of the corresponding metric, is provided. Findings This tool can be considered a suitable method to achieve simultaneously a dual purpose to establish time standards and to identify the hidden losses that account for most of the recorded time of manual assembly activities, estimating the impacts of potential corrective actions in terms of both efficiency and effectiveness. Practical implications OTE provides practitioners with an operative tool useful to highlight the points where the major inefficiencies take place in industries producing large complex items via manual assembly lines. Its practical application is demonstrated using a case study concerning a manufacturer of train wagons. Originality/value One distinctive, and contemporarily appealing, feature of OTE with respect to other analogous KPIs is that it provides a breakdown structure for process losses that simplifies the task of evaluating the current performances and, at the same time, individuates both the source of losses and the corresponding corrective actions.

scholarly journals Improving Small-quantity Assembly Lines for Complex Industrial Products by Adapting the Failure Process Matrix (FPM): A Case Study

Procedia CIRP ◽  
2014 ◽  
Vol 17 ◽  
pp. 236-241 ◽  
Author(s):  
Mark Hillmann ◽  
Sven Stühler ◽  
Alexander Schloske ◽  
Dirk Geisinger ◽  
Engelbert Westkämper
Keyword(s):  
Failure Process ◽  
Assembly Lines ◽  
Industrial Products
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