Design Improvement of Assembly Workplace through Ergonomic Simulation and Analysis Using DELMIA

2015 ◽  
Vol 21 ◽  
pp. 238-246 ◽  
Author(s):  
Shaban Usman ◽  
Hai Tao Zhu ◽  
Mazhar Ul Haq
Keyword(s):  
Diesel Engine ◽  
Process Improvement ◽  
Assembly Line ◽  
Virtual Assembly ◽  
Software Tool ◽  
Process Time ◽  
Simulation Environment ◽  
Manual Assembly ◽  
Time And Energy

The aim of this research is to demonstrate the ergonomic process modeling and simulation of manual assembly work through virtual assembly approach in order to present workplace and process improvement prior to their physical prototyping. In this regard, a case study has been carried out to analyze an assembly workplace of a diesel engine by ergonomics simulation and virtual assembly approach. DELMIA, a software tool, has been exploited for the ergonomic simulation and analysis in virtual assembly environment. The case study demonstrates several improvements in the ergonomics of the operators performing assembly on production line of the diesel engine. The assembly process of last few stations of the diesel engine simulated and analyzed on DELMIA in order to exhibit the advantages of the virtual assembly approach to the workplace deign and saving of process time and energy expenditure of operator. On last station of the engine assembly line, parts are assembled relatively at higher and complex positions and it is difficult for an operator to assembly them. Since, the assembly is carried out on conveyor; it is not convenient to change the height of conveyor to overcome the problem. Therefore, height of the floor of last work station is altered / increased. In order to achieve the increased floor height, a number of benches of variable heights are placed on the floor on the last working station one by one in the simulation environment and simulation of the process is carried out. The simulation results show that the ergonomics of operators have significantly changed by altering working height of the operator. Simulation of second last and other working station has also been performed by altering the height of the floor, but no improvements in the ergonomics of the operator observed for these stations

Lean production in manual assembly line — A case study

2012 ◽  
Author(s):  
Low Shye Nee ◽  
Goh Wen Juin ◽  
Fow Jun Yan ◽  
Chan Yee Theng ◽  
S. Kamaruddin
Keyword(s):  
Assembly Line ◽  
Lean Production ◽  
Manual Assembly

2313 Regaining Productivity Through Line Balancing : A Case Study in an Electrical Manual Assembly Line

2014 ◽  
Vol 2014.24 (0) ◽  
pp. _2313-1_-_2313-6_
Author(s):  
Adi SAPTARI ◽  
Jia Xin LEAU ◽  
Nor Akramin MOHAMAD ◽  
Effendi MOHAMAD
Keyword(s):  
Assembly Line ◽  
Line Balancing ◽  
Manual Assembly

Using Delmia V5 for Human Activity Improvement in an Assembly Line Production

2014 ◽  
Vol 657 ◽  
pp. 353-358 ◽  
Author(s):  
Rares Adrian Ghinea ◽  
Daniela Popescu ◽  
Călin Neamțu ◽  
Dan Hurgoiu ◽  
Florin Popister
Keyword(s):  
Virtual Environment ◽  
Human Activity ◽  
Manufacturing Industry ◽  
Assembly Line ◽  
Pneumatic Actuator ◽  
Assembly Process ◽  
Manual Assembly ◽  
Line Production ◽  
Simulation And Optimization

This paper presents a methodology for the simulation and optimization in a virtual environment of a manual assembly process. For validation of the methodology the authors chose an assembly process that is already used in the manufacturing industry. In the first step of the proposed methodology the existing process is simulated and then based on the simulation the activities and equipment involved are being analyzed and in the next step the assembly process is to be optimized using simulation and a series of modification vectors such as: layout, devices, tools and movement sequences. The case study presented in the paper aims to optimize the assembly process of a pneumatic actuator of a butterfly type valve.

Simulation-Based Comparison of Pull-Push Systems in Motorcycle Assembly Line

2012 ◽  
Vol 241-244 ◽  
pp. 1507-1513
Author(s):  
Umchid Sutee ◽  
Prasad K.D.V. Yarlagadda
Keyword(s):  
Assembly Line ◽  
Assembly Line Balancing ◽  
Influential Factors ◽  
Simulation Software ◽  
Process Time ◽  
Pull System ◽  
Work In Process ◽  
Assembly Line Balancing Problem ◽  
Systems Simulation

To investigate the effects of adopting a pull system in assembly lines in contrast to a push system, simulation software called “ARENA” is used as a tool in order to present numerical results from both systems. Simulation scenarios are created to evaluate the effects of attributes changing in assembly systems, with influential factors including the change of manufacturing system (push system to pull system) and variation of demand. Moreover, pull system manufacturing consists of the addition attribute, which is the number of buffer storage. This paper will provide an analysis based on a previous case study, hence process time and workflow refer to the journal name “Optimising and simulating the assembly line balancing problem in a motorcycle manufacturing company: a case study” [2]. The implementation of the pull system mechanism is to produce a system improvement in terms of the number of Work-In-Process (WIP), total time of products in the system, and the number of finished product inventory, while retaining the same throughput.

An Integrated Approach to the Planning of Manual Assembly Lines

2015 ◽  
Author(s):  
George Pintzos ◽  
Markos Matsas ◽  
Christos Triantafyllou ◽  
Nikolaos Papakostas ◽  
George Chryssolouris
Keyword(s):  
Computer Aided Design ◽  
Manufacturing Systems ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Optimization Techniques ◽  
Line Balancing ◽  
Assembly Planning ◽  
Manual Assembly ◽  
Wide Range

Manual assembly planning methodologies have been in the center of industrial and academic research for many decades, since the manual assembly costs may often account for even half of the total manufacturing expenses. The existing and emerging manufacturing trends, such as mass customization and personalization, require fast responses when it comes to the conception and realization of the relevant manufacturing systems. Even though, work methodologies, such as concurrent engineering, have been proposed and applied, gaps still exist among product development, configuration and manufacturing. The Current Product Lifecycle (PLM) systems focus on the coordination of activities among engineers of different disciplines. However, they are unable to provide actual decision support functionality to decision makers. Moreover, solutions for the different phases of assembly planning have been proposed, without nevertheless taking into account the holistic nature of assembly planning that spans the different engineering phases. The study presented in this paper is based on a methodology that integrates three distinct steps, regarding assembly planning; the generation of assembly related information, from the Computer Aided Design (CAD) files of an assembly, the calculation of the relevant process times from functions, generated through empirical measurements and the assembly line balancing of a line, based on the information gathered. The innovative aspect of this approach relies on the advancement of the relevant technologies as well as on their integration into a common working practice. The methodology enables the estimation of production related values in the later phases of product design or in the early phases of manufacturing planning. The generation of assembly precedence diagrams is made in an automatic way through the extraction of information on collision detection and the parts’ relations. This application is developed in the form of an add-on to a commercial CAD software suite. It utilizes features that are available in a wide range of such systems. The second step relies on the identification of specific features of parts, such as dimensions and mass. This information is then used as input in the functions already proposed in the academic literature for the estimation of the relevant process times for each part. Finally, the assembly line balancing is performed through the generation of the precedence diagram and the estimated process times, via a web-based service, which makes use of advanced optimization techniques. In order for this methodology to be evaluated, a case study is presented by using the CAD file of an automotive sub-assembly. The case study demonstrates each step separately, beginning with the generation of the precedence diagram down to the balancing of the assembly line.

A Productivity Improvement of a Packing Line

2015 ◽  
Vol 789-790 ◽  
pp. 1240-1244
Author(s):  
Peeyapach Jitchaiyaphum ◽  
Suksan Prombanpong
Keyword(s):  
Production Line ◽  
Assembly Line ◽  
Waste Reduction ◽  
Line Balancing ◽  
Assembly Lines ◽  
Customer Demand ◽  
Productivity Improvement ◽  
Manual Assembly ◽  
Line Design

The purpose of this paper is to demonstrate a productivity improvement through waste reduction and line balancing. One of the obstacles of a manual assembly line nowadays is an awkward line design with over manpower, a lot of wastes, and low balance efficiency. As a result, the production line may not satisfy customer demand and ends up with low production line efficiency. This is due to the fact that this type of production line is operated by human and the customer demand or requirements are frequently fluctuated. Human workers are prone to make mistakes, inefficient, and unorganized. Thus, the major causes of production line down time are discussed with suggestion of remedy actions to improve the productivity. In addition, calculation of line balancing is demonstrated. One of the actual manual assembly lines will be used as a case study. It is found that after improvement line balance efficiency is increased from 46.49 to 86.66 percent with the productivity improvement of 159 percent.

Efficiency Improvement of Thermistor Sensor Production Line through Line Balancing Methods

2015 ◽  
Vol 778 ◽  
pp. 240-244
Author(s):  
Ketsada Khamwiset ◽  
Suksan Prombanpong
Keyword(s):  
Assembly Line ◽  
Wait Time ◽  
Line Balancing ◽  
Efficiency Improvement ◽  
Assembly Lines ◽  
Manual Assembly ◽  
Lost Time ◽  
Effectiveness And Efficiency ◽  
Back Order

The purpose of this paper is to demonstrate an efficiency improvement of assembly line by through line balancing method. By reducing lost time in assembly line caused working time each station does not equal. There was a wait time between work stations. As a result, the effectiveness and efficiency of the assembly line low. Will be affected the delivery of product to customers is not enough or back order. In addition, calculation of line balancing is demonstrated. One of the actual manual assembly lines will be through as a case study. It is found that after improvement line balance efficiency is increased from 63.62 to 89.52 percent with the efficiency improvement of 25.9 percent.

scholarly journals Automated Design and Integration of Asset Administration Shells in Components of Industry 4.0

Sensors ◽  
2021 ◽  
Vol 21 (6) ◽  
pp. 2004
Author(s):  
Jakub Arm ◽  
Tomas Benesl ◽  
Petr Marcon ◽  
Zdenek Bradac ◽  
Tizian Schröder ◽  
...  
Keyword(s):  
Industry 4.0 ◽  
Assembly Line ◽  
Discrete Event ◽  
Virtual Assembly ◽  
Substantial Part ◽  
Automated Generation ◽  
Open Platform ◽  
Manufacturing Management ◽  
The Given

One of the central concepts in the principles of Industry 4.0 relates to the methodology for designing and implementing the digital shell of the manufacturing process components. This concept, the Asset Administration Shell (AAS), embodies a systematically formed, standardized data envelope of a concrete component within Industry 4.0. The paper discusses the AAS in terms of its structure, its components, the sub-models that form a substantial part of the shell’s content, and its communication protocols (Open Platform Communication—Unified Architecture (OPC UA) and MQTT) or SW interfaces enabling vertical and horizontal communication to involve other components and levels of management systems. Using a case study of a virtual assembly line that integrates AASs into the technological process, the authors present a comprehensive analysis centered on forming AASs for individual components. In the given context, the manual AAS creation mode exploiting framework-based automated generation, which forms the AAS via a configuration wizard, is assessed. Another outcome consists of the activation of a virtual assembly line connected to real AASs, a step that allows us verify the properties of the distributed manufacturing management. Moreover, a discrete event system was modeled for the case study, enabling the effective application of the Industry 4.0 solution.

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