Optimizing the Tolerance for the Products with Multi-Dimensional Chains via Simulated Annealing

The assembly is the last process of controlling the product quality during manufacturing. The installation guidance should provide the appropriate assembly information, e.g., to specify the components in each product. The installation guidance with low quality results in rework or the resource waste from the failure products. This article extends the dimensional chain assembly problem proposed by Tsung et al. to consider the multiple dimensional chains in the product. Since there are multiple dimensional chains in a product, the installation guidance should consider inseparability and acceptability as computing the installation guidance. The inseparability means that the qualities of all dimensional chains in the part should be evaluated together without separation, while the acceptability stands for that the size of each product should be satisfied with the specification. The simulated annealing (SA) algorithm is applied to design the assembly guidance optimizer named as AGOMDC to compute the assembly guidance in the dimensional chain assembly problem with multiple dimensional chains. Since SA has high performance in searching neighbor solutions, the proposed approach could converge rapidly. Thus, proposed AGOMDC could be applied in real-world application for the implementation consideration. The simulations consist of two parts: the feasibility evaluation and the algorithm configuration discussion. The first part is to verify the inseparability and acceptability that are the hard constraints of the assembly problem for the proposed AGOMDC, and the second one is to analyze the algorithm configurations to calculate the assembly guidance with 80% quality. The simulation results show that the inseparability and acceptability are achieved, while the proposed AGOMDC only requires more than two seconds to derive the results. Moreover, the recommended algorithm configurations are derived for evaluate the required running time and product quality. The configurations with product quality 80% are that the temperature descent rate is 0.9, the initial temperature is larger than 1000, and the iteration recommended function is derived based on the problem scale. The proposed AGOMDC not only helps the company to save the time of rework and prevent the resource waste of the failure products, but is also valuable for the automatic assembly in scheduling the assembly processes.

Classification and Quantification of Human Error in Manufacturing: A Case Study in Complex Manual Assembly

Manual assembly operations are sensitive to human errors that can diminish the quality of final products. The paper shows an application of human reliability analysis in a realistic manufacturing context to identify where and why manual assembly errors occur. The techniques SHERPA and HEART were used to perform the analysis of human reliability. Three critical tasks were selected for analysis based on quality records: (1) installation of three types of brackets using fasteners, (2) fixation of a data cable to the assembly structure using cushioned loop clamps and (3) installation of cap covers to protect inlets. The identified error modes with SHERPA were: 36 action errors, nine selection errors, eight information retrieval errors and six checking errors. According to HEART, the highest human error probabilities were associated with assembly parts sensitive to geometry-related errors (brackets and cushioned loop clamps). The study showed that perceptually engaging assembly instructions seem to offer the highest potential for error reduction and performance improvement. Other identified areas of action were the improvement of the inspection process and workers’ provision with better tracking and better feedback. Implementation of assembly guidance systems could potentially benefit worker’s performance and decrease assembly errors.

Projection-based augmented reality system for assembly guidance and monitoring

Purpose This study aims to monitor and guide the assembly process. The operators need to change the assembly process according to the products’ specifications during manual assembly of mass customized production. Traditional information inquiry and display methods, such as manual lookup of assembly drawings or electronic manuals, are inefficient and error-prone. Design/methodology/approach This paper proposes a projection-based augmented reality system (PBARS) for assembly guidance and monitoring. The system includes a projection method based on viewpoint tracking, in which the position of the operator’s head is tracked and the projection images are changed correspondingly. The assembly monitoring phase applies a method for parts recognition. First, the pixel local binary pattern (PX-LBP) operator is achieved by merging the classical LBP operator with the pixel classification process. Afterward, the PX-LBP features of the depth images are extracted and the randomized decision forests classifier is used to get the pixel classification prediction image (PCPI). Parts recognition and assembly monitoring is performed by PCPI analysis. Findings The projection image changes with the viewpoint of the human body, hence the operators always perceive the three-dimensional guiding scene from different viewpoints, improving the human-computer interaction. Part recognition and assembly monitoring were achieved by comparing the PCPIs, in which missing and erroneous assembly can be detected online. Originality/value This paper designed the PBARS to monitor and guide the assembly process simultaneously, with potential applications in mass customized production. The parts recognition and assembly monitoring based on pixels classification provides a novel method for assembly monitoring.

Computing the Assembly Guidance for Maximizing Product Quality in the Virtual Assembly

Assembly is the final process of manufacturing, and a good assembly plan reduces the effect of the tolerance generated in the early stages by the tolerance elimination. In the current assembly lines, the assemblers pick up the workpieces and install them together by the assembly instructions. When the workpieces are oversize or undersize, the product can not be installed correctly. Therefore, the assembler considers the secondary processing to fix the tolerance and then installs them together again. The product could be installed, but the product quality may be reduced by the secondary process. So, we formulate the assembly process as a combinatorial optimization problem, named by the dimensional chain assembly (DCA) problem. Given some workpieces with the corresponding actual size, computing the assembly guidance is the goal of the DCA problem, and the product quality is applied to represent the solution quality. The assemblers follow the assembly guidance to install the products. We firstly prove that the DCA problem is NP-complete and collect the requirements of solving the DCA problem from the implementation perspective: the sustainability, the minimization of computation time, and the guarantee of product quality. We consider solution refinement and the solution property inheritance of the single-solution evolution approach to discover and refine the quality of the assembly guidance. Based on the above strategies, we propose the assembly guidance optimizer (AGO) based on the simulated annealing algorithm to compute the assembly guidance. From the simulation results, the AGO reaches all requirements of the DCA problem. The variance of the computation time and the solution quality is related to the problem scale linearly, so the computation time and the solution quality can be estimated by the problem scale. Moreover, increasing the search breadth is unnecessary for improving the solution quality. In summary, the proposed AGO satisfies with the necessaries of the sustainability, the minimization of computation time, and the guarantee of product quality for the requirements of the DCA, and it can be considered in the real-world applications.