Development of a Methodology for Cost Estimation in Robot Assembly

1998 ◽  
Author(s):  
Oliver Tischner ◽  
A. H. Soni
Keyword(s):  
Cost Estimation ◽  
Manufacturing Systems ◽  
Industrial Robots ◽  
Assembly Planning ◽  
Assembly System ◽  
Assembly Systems ◽  
Production Volume ◽  
Investment Planning ◽  
Flexible Assembly ◽  
Flexible Operation

Abstract The developments in today’s industries put the companies under increasing pressure concerning time and costs. This forces them to, among other measures, rationalize and automates the manufacturing systems, including the assembly systems. To reduce the risks of investments and enhance the investment planning, accurate calculation methodologies for assembly planning systems are necessary. There are a number of ways to lay out an assembly system. An assembly system may be designed for a manual operation, an automatic operation, or a flexible operation. Industrial robots are extensively used in such flexible assembly systems. Production volume and cost per assembled part depend heavily on how such a flexible cell is designed and on the robot being used. Boothroyd and Dewhurst have proposed an approach to arrive at evaluating robot integrated assembly cells. This approach is based on the manipulation of the part before presenting it for an assembly and the number of robot arms in the assembly cell. It does not account for the flexibility (number of robot axes, specific types of robots) the various industrial robots offer. Consequently, any evaluation made on this basis is expected to provide inaccurate answers.

Agile Montage*/Agile assembly – Assembly planning and assembly system as integral elements of factory planning

2019 ◽  
Vol 109 (09) ◽  
pp. 622-627
Author(s):  
P. Burggräf ◽  
M. Dannapfel ◽  
T. Adlon ◽  
A. Riegauf ◽  
K. Müller ◽  
...  
Keyword(s):  
Product Development ◽  
Assembly Planning ◽  
Assembly System ◽  
Agile Methods ◽  
Assembly Systems ◽  
Manufacturing Companies ◽  
Economic Optimization ◽  
Customer Needs ◽  
Factory Planning ◽  
Solution Approach

Produzierende Unternehmen intensivieren aufgrund zunehmend volatiler Kundenbedürfnisse die Anwendung agiler Produktentwicklungsansätze. Ziel des Beitrags ist die Einführung eines Konzepts zur Befähigung dieser dynamischen Produktentwicklung in der Montage. Der integrative Lösungsansatz basiert auf der wirtschaftlichen Optimierung des Agilitätsgrades von Montagesystemen sowie dem selektiven Einsatz agiler Methoden in der traditionell plangetriebenen Montageplanung als Teil der Fabrikplanung.   To meet more volatile customer needs, manufacturing companies increasingly make use of agile product development approaches. This article aims to introduce a concept to enable for dynamic product development in assembly. This integrative solution approach is based on the economic optimization of the degree of agility of assembly systems and on the selective use of agile methods in traditional, plan-driven assembly planning as part of factory planning.

Identification of Assembly System Configuration for Cyber-Physical Assembly System Planning

2016 ◽  
Vol 840 ◽  
pp. 24-32 ◽  
Author(s):  
Rainer Müller ◽  
Matthias Vette ◽  
Leenhard Hörauf ◽  
Christoph Speicher
Keyword(s):  
Planning Process ◽  
Assembly Planning ◽  
Shop Floor ◽  
Assembly System ◽  
Assembly Systems ◽  
Virtual Model ◽  
System Configuration ◽  
Virtual Planning ◽  
Actual Configuration ◽  
Modular Structures

To respond to challenges created by an increase of product variants, multi-variant lines are used as today’s assembly systems. In these multi-variant lines different product variants with diverse lot sizes can be efficiently assembled. These assembly systems are characterized by modular structures that allow assembly system adaptation by reconfiguration.The variety of parameters to be considered from the product’s perspective and the correct allocation of different assembly modules increases the complexity when planning these systems. This complexity makes it difficult to successfully plan and implement production processes. Therefore, digital planning tools and models have to be used to schedule new product variants and to verify that the assembly is possible, given by the modules in the assembly line.Due to its ability to reconfigure, the actual assembly system is adaptable to different product variants. But these modifications are performed by the operator on the shop floor and are often neither properly documented nor communicated to the assembly planer. Thus, the configuration status in reality and the virtual model differ from each other. Using the outdated model for planning without taking into account the changes can result in an unrealizable assembly plan.To overcome this problem, the presented paper introduces a method and technical system to identify the actual assembly system configuration before the assembly planning is done. Due to the subsequent update of the virtual model depending on the actual configuration, the assembly planner is supported with the latest version of the assembly system configuration. Furthermore, the assembly planning process is improved, because possible failures are detected in advance in the virtual planning environment.

A novel approach to flexible robotic assembly systems

Robotica ◽  
1995 ◽  
Vol 13 (6) ◽  
pp. 583-589
Author(s):  
Samir B. Billatos
Keyword(s):  
Industrial Robots ◽  
Robotic Assembly ◽  
Assembly Systems ◽  
Flexible Assembly Systems ◽  
Flexible Assembly ◽  
Novel Approach ◽  
Robotic Wrist ◽  
The Way

SummaryThis paper presents a novel approach to designing and manufacturing of a universal gripper to be used with industrial robots in flexible assembly systems. Important issues that impact greatly on the efficiency of the gripper are also discussed in this paper. Such issues include the degree of compliance allowed by the robotic wrist and the way these grippers are actuated. The gripper has been proven to be extremely flexible and low in cost.

Assembly System Reconfiguration Planning Using Genetic Algorithm

2008 ◽  
Author(s):  
A. Bryan ◽  
S. J. Hu ◽  
Y. Koren
Keyword(s):  
Genetic Algorithm ◽  
Manufacturing Systems ◽  
Cost Effective ◽  
New Product ◽  
Assembly System ◽  
Assembly Systems ◽  
Reconfigurable Manufacturing ◽  
Product Families ◽  
System Reconfiguration ◽  
Reconfiguration Planning

Due to increased competition, the rate at which manufacturers introduce new product families to the market is increasing. However, the cost of changing manufacturing facilities to produce new product families can outweigh the benefits obtained from increased revenue. Reconfigurable Manufacturing Systems (RMSs) have been proposed as a cost effective strategy for manufacturing product families. Although methods for measuring RMS scalability and convertibility exist, there is a lack of methods for obtaining reconfiguration plans for assembly systems. This paper introduces assembly system reconfiguration planning (ASRP) as method to obtain reconfiguration plans for assembly systems. A genetic algorithm is developed for solving the ASRP problem.

Implementation framework for a fully flexible assembly system (F-FAS)

2015 ◽  
Vol 35 (1) ◽  
pp. 114-121 ◽  
Author(s):  
Christian Finetto ◽  
Giulio Rosati ◽  
Maurizio Faccio ◽  
Aldo Rossi
Keyword(s):  
Manufacturing Systems ◽  
Industrial Applications ◽  
Assembly System ◽  
Automated Manufacturing Systems ◽  
Implementation Framework ◽  
Content Type ◽  
Practical Applications ◽  
Flexible Assembly ◽  
Set Up ◽  
System F

Purpose – This paper aims to provide a framework for the choice, design, set-up and management of a fully flexible assembly system (F-FAS). Many industrial applications for small batch productions require highly flexible automated manufacturing systems. Moreover, some extensions of the F-FAS concept are provided. Design/methodology/approach – The paper reviews recent findings regarding the F-FAS with a top-down approach, and defines an integrated implementation framework. This framework is structured into three strictly correlated phases, and the presented procedure is organized to be readily used for new industrial applications. Practical applications are presented to show how the system can satisfy flexibility demands in a variety of cases. Findings – The proposed framework is organized in three steps: convenience analysis of the F-FAS compared to a traditional flexible assembly system; an optimal design of the feeder; a choice of the set-up and sequencing algorithm yielding the highest throughput. Following these steps, the F-FAS can become an effective solution for small batch productions with frequent reconfigurations. However, due to the limited throughput, the system is not well suited for large batches. Originality/value – The presented framework allows to implement an F-FAS for a given industrial application, and to evaluate its efficacy with respect to other assembly technologies. Moreover, with the same implementation framework, the F-FAS concept can be applied to production fields that are different from assembly, as shown by the provided examples. This represents an important element of originality and of interest for its strong practical implications in different production environments.

Linking product design to flexibility in an assembly system: a case study

2017 ◽  
Vol 28 (5) ◽  
pp. 610-630 ◽  
Author(s):  
Narges Asadi ◽  
Mats Jackson ◽  
Anders Fundin
Keyword(s):  
Product Design ◽  
Global Market ◽  
Assembly System ◽  
Assembly Systems ◽  
Research Approach ◽  
Manufacturing Companies ◽  
Flexible Assembly Systems ◽  
Content Type ◽  
Flexible Assembly

Purpose The recent shift towards accommodating flexibility in manufacturing companies and the complexity resulting from product variety highlight the significance of flexible assembly systems and designing products for them. The purpose of this paper is to provide insight into the requirements of a flexible assembly system for product design from the assembly system’s standpoint. Design/methodology/approach To fulfil the purpose of the paper, a literature review and a case study were performed. The case study was conducted with an interactive research approach in a global market leader company within the heavy vehicle manufacturing industry. Findings The findings indicate that common assembly sequence, similar assembly interfaces, and common parts are the main requirements of a flexible assembly system for product design which reduce complexity and facilitate various flexibility dimensions. Accordingly, a model is proposed to broaden the understanding of these requirements from the assembly system’s standpoint. Research limitations/implications This study contributes to the overlapping research area of flexible assembly systems and product design. Practical implications The proposed model is largely based on practical data and clarifies the role of product design in facilitating flexibility in an assembly system. It can be used by assembly managers, assembly engineers, and product designers. Originality/value The key originality of this paper compared to the previous studies lies in presenting a novel assembly-oriented design model. The model enhances understanding of a flexible assembly system’s requirements for product design with regard to reducing complexity and managing variation in a flexible assembly system. These requirements can be applied to product design across various product families within a company’s product portfolio.

Application of Assembly System Partial Units for the Development of Intelligent Assembly Cell

2013 ◽  
Vol 309 ◽  
pp. 3-11
Author(s):  
Roman Ruzarovsky ◽  
Nina Danišová ◽  
Karol Velíšek
Keyword(s):  
Manufacturing Systems ◽  
Intermediate Stage ◽  
Assembly System ◽  
Flexible Assembly ◽  
Cell Functions ◽  
Time Interaction ◽  
Assembly Cell ◽  
Reaction Data ◽  
Intelligent Behavior ◽  
The Individual

Development of intelligent assembly cell conception includes new solution kind of how to create structures of automated and flexible assembly system. Intelligent behavior of the system as the control system will repose on monitoring of important parameters of the system in the real time. Interaction information will be taken from flexible reaction data. This kind of flexible conception realization of intelligent assembly systems brings many advantages such as, cell will brings flexible reactions of the system to the manufacturing changes, build up area saving, lover building costs, higher using effects of whole device. This conception is developed at Institute of the manufacturing systems and applied mechanics and continues at an intermediate stage of the project. The paper is presented the description of the new conception philosophy, design of the individual units in the system characterized as an intelligent assembly cell, functions principles and expected proceedings in the next phases of the project.

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