How can you optimize assembly for complex products?

Analyzing product requirements is crucial for optimizing assembly processes, especially for complex products.In essence, analyzing product requirements provides a roadmap for optimizing assembly processes, enhancing efficiency, reducing costs, and ensuring the final product meets both quality standards and customer expectations.

Antes de iniciar qualquer processo de montagem, é muito importante que se realize um planejamento detalhado, Definindo-se quais são os materiais mais apropriados e necessários. Também a elaboração de uma sequência de montagem por módulos pode ser uma forma de agilizar a montagem, podendo garantir uma produção mais ágil.

As per the product development and DFM / DFA check the all requirements and development phases A. Bom and non bom material list updated. B. The testing function features C. Customer voice D. Delivery and quantity quality

Als erstes muss das Produkt analysiert werden. Grundlage ist dabei die Stückliste (BOM), die Baugruppen und Einzelteile beinhalten sollte. Wichtig ist dabei die Konfigurationsoptionen zu kennen. Dabei sollte bei einem komplexen Produktportfolio eine Segmentierung vorgenommen werden, um verschiedene Ausstattungen in Ausstattungslinien zu bündeln. Die können dann als Referenz für die Ausplanung der Montage genutzt werden.

A basic setup is the use of a shop order card which contains detail bill of materials, customer information, order information, manufacturing instructions and product specifications.

Bei der Entwicklung der Montagekonzepte können verschiedene Organisationsformen (z.B. Montagelinien oder Einzelplatzmontage) sowie Montagetechniken (manuell, semiautomatisch, oder automatiert) gewählt werden. Die Auswahl hängt an der Stückzahl, der Varianz in den Produkten, sowie der Schankung an Stückzahl und Varianz bzw. der notwendigen Flexibiliät. Dieses Montagekonzept liegt die Grundlage für die Arbeitsplatzgestaltung und die Austaktung der Montage. Eine Austaktung ist nicht nötig, wenn nicht taktgebundene Organisationsformen, wie die die Matrix-Produktion, gewählt werden.

After careful analysis of product components, customer needs, and tolerances, choosing the right assembly method is next. Hybrid assembly method which consists of both humans and machines, can be utilized. Create a detailed and robust assembly process; and ensure all stakeholders are trained before execution. This will improve the results of the assembly process.

Proper calibration fixtures and lean process flow will help to identify gaps to meet assy requirements, identify sources to get proper controls and poka yokes defined as much is possible to avoid mistakes

Optimal assembly methododoligies starts with requirements. If you need access for service or certain modules require replacement then design should anticipate and plan for manual methods. Wherever possible it is preffered to making things that can only go together one way or are a/symmetric such that any accepted orientation works. There is nothing worse than assembling something then realizing it is 180 degrees from where it needs to be 3 steps later. In all cases minimizing fastener types reduces error and complexity. The question of manual, automated or hybrid really boils down to volume, complexity, and confidance. As variation goes up the case for automation goes down but hybrid may be the best balance of cost and control.

The appropriate assembly methods depend on the materials and components involved. Common methods include welding for metals, adhesive bonding for lightweight materials, and screws/bolts for joining parts. Consider the specific requirements of your project, such as strength, durability, and cost, when selecting assembly methods

Für die konkrete Gestaltung der Montage sollten Referenzarbeitsplätze entwickelt werden, die sich am Montagekonzept orientieren und Platz für das Produkt, die Mitarbeiter und Maschinen, die Werkzeuge und die Bereitstellung der Materialien berücksichtigen. Dazu muss die Zugänglichkeit der jeweiligen Bereiche insbesondere für den Nachschub von Materialien und dem Weitertransport des Produkte gewährleistet werden. Auf Basis der Gestaltung der einzelnen Arbeitsplätze kann ein gesamtes Montagelayout auf Basis der benötigten Anzahl an Arbeitsplätzen entwickelt werden.

Additional/expanded points to consider: Are you setting up a greenfield (brand new, you get to customize the build to match your needs) or brownfield facility (an already existing or developed location) Batch or Continuous flow. Continuous flow may maximize throughput, maximize machine uptime or best fit the ‘ideal’. However, that optimal may require significant resources, or you may be limited by relevant regulations that require batch monitoring or batch testing, etc… just as with quality, there is a cost to uptime and efficiency that must be balanced for your goals, resources, and circumstances. Get out of the office and go do the work. Have you tried doing the assembly yourself or consulted those who do the work?

A clear and concise set of instructions and necessary training can make a huge impact on the quality of the resulting assembly. That alone doesnt control the process. Checklists and manufacturing travelers help to make sure critical steps are not missed. Another essential element, critical to quality assurance, are checks in process and at completion. Sub-assembly and module testing to ensure completeness and accuracy help to support the work instructions and verify the assembly process outputs.

To monitor and control assembly performance, establish key performance indicators (KPIs) such as production efficiency, defect rates, and cycle times. Implement real-time monitoring systems, conduct regular quality checks, and use data analytics to identify areas for improvement. Continuous process optimization and employee training contribute to better assembly performance

Besides the continuous improvement, the early steps of process definition is highly critical as well. Asses all of your production risks and invest in DFM stage to optimise the assembly from early design stages. In this way you can get a better production process which will ease on the technician, save money and add value to the production line.

Fully agree and more: get a mix of staff knowledge in a wide range of industry, from expert till enthusiastic just graduated, and give them responsibility via tailor made tasks. See complexity at helicopter-view also helps.

Good records and data especially in regulated markets are the keys to process improvements. Unfortunately, all the data and process monitoring or engineering efforts to optimize will likely miss the biggest opportunities. The people actually building and using the device or process / outputs have unique insights. Their feedback can drive the greatest improvements.

Create a loop for constant feedback. Automated feedback generation is a good move. Collect as much feedback as possible from your assemble line. Act on this feedback quickly and continuously.

In my experience, when looking to improve the assembly process post-install getting the teams input is invaluable. The trades/assembly workers are the ones to work on the process on a daily basis and likely may have already found the best way to improve the build. Never limit yourself from hearing opinions at all levels.

In the top-down approach to design model assembly, you work big-picture first, starting with the overall structure and defining the major components before diving into individual parts. It gives room for greater control, efficient design and faster iterations.

I would add modularity as a factor to consider in design for manufacturability and assembly (DFMA) for complex products. When a complex device is comprised of several functional systems optimal manufacturing can be achieved by developing your system archateure modularly. Each module can be built and tested independently of the overall system. The final integration is simplified as an assembly of modules and the overall process benefits from being able to independently optimize each module or sub-system without up-stream or down-stream impact.

Complex in terms of manufacturing means high precision manufacturing. Usage of standard during design and following the to production processes is easy to achieve.