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    Implementation and Line Balancing of Assembly Line of ABS

    Motor for Improvement of Assembly Productivity

    Brain Korea 21 Logistics Team

    Industrial Engineering / Pusan National University

    Author :

    S.T. Pyo(12pt, bold)

    (Assembly Automation Lab., Industrial Engineering, Pusan National University)

    Thesis supervisor :

    Prof. H.S. Mok(12pt, bold)

    (Assembly Automation Lab., Industrial Engineering, Pusan National University)

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    2 Implementation and Line Balancing of Assembly Line of ABS Motorfor Improvement of Assembly Productivity

    Abstract

    This paper proposes a implementation procedure of flexible assembly line of ABS motor which

    is composed of four subassemblies, yoke, grommet, housing, armature. The characteristics of

    ABS motor and assembly process are analyzed, and then the automation possibility of each unit

    process is decided to decrease an assembly time and cost. The assembly machines and facilities

    are selected for automatic assembly, and then the layout of the selected facilities is performed.Task allocation of each worker is achieved by assembly line balancing to increase an assembly

    productivity and efficiency.

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    Contents

    Abstract .. . .. 2

    List of frequently used symbols . ..4

    1 Introduction ..5

    2 Analysis of assembly object and process . .6

    2.1 Analysis of part and subassembly of ABS motor.6

    2.2 Analysis of assembly process of ABS motor.. .6

    3 Implementation of assembly line of ABS motor ..8

    3.1 Determination of automation possibility of assembly process automation. .8

    3.2 Determination of assembly equipment of assembly process...9

    3.3 Layout of assembly machinery equipment.....11

    3.4 Work assignment and line balancing......12

    4 Conclusion .. 16

    5 Reference . . .. .17

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    4 Implementation and Line Balancing of Assembly Line of ABS Motorfor Improvement of Assembly Productivity

    List of frequently used symbols

    K = Number of works

    CT = Cycle time

    Ti = Working hours of each worker

    Tmax = Maximum working hours of each worker

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    1 Introduction

    Automatic assembly process can produce a product quality with consistently high reliability

    compared with manual assembly. But, to implement an automatic assembly line, there are some

    problems.

    First, assembly process has technical and economical risk than other processes due to itsaccumulative errors. Second, it should be implemented a different assembly system according to

    products. Therefore, when it has to produce fixed equipment and has limited investment cost

    and feeding area, it needs a flexible assembly system that includes a manual assembly for

    specific assembly process.

    The research of assembly line implementation has been focused on invest analysis which

    determines the best investment cost with limited capital and line balancing for the maximum

    efficiency of assembly line. Therefore it is needed flexible assembly system by mixing of

    automatic assembly and manual assembly.

    Study for implementation of assembly line is focused on assembly line balancing, which is

    maximizing investment analysis and efficiency of assembly line. And it has been also studied a

    DFA(Design for Assembly) for ease of assembly and assembly automation, devices for parts

    transporting, arrangement, feeding and joining, machines and equipments of arrangement and

    evaluation for efficient usage .

    In this research, we suggest an implementation procedure of flexible assembly line of ABS

    motor, and a method of assembly line balancing which can increase an assembly productivity

    and efficiency.

    First, new assembly procedure is determined by characteristics analysis of ABS motor and

    analysis of finished assembly line. Second, determination of automation possibility for each of

    assembly process by characteristics of ABS motor and assembly process, volume of products

    and cycle time, etc. Third, the assembly process determines assembly devices. Finally, machine

    layout and work allocation are determined by object product volume in cycle time.

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    6 Implementation and Line Balancing of Assembly Line of ABS Motorfor Improvement of Assembly Productivity

    2 Analysis of assembly object and process

    2.1 Analysis of part and subassembly of ABS motor

    There are 4 subassemblies of ABS motor; Yoke subassembly, Housing subassembly, Armature

    subassembly, Grommet subassembly. Yoke subassembly is composed of 9 parts and 5 kinds of

    parts; Yoke, magnet, magnet holder, bearing, bolt. Housing is made up of 4 parts; housing,bearing, bolt. Grommet subassembly has 24 parts; brush holder, brush spring, cable, etc. And

    armature subassembly is composed of 5 parts; shaft, commy, core, o-ring etc.

    Fig. 1 Subassemblies of ABS motor

    Fig.1 shows 4 subassemblies of automobile ABS motor; yoke housing, armature and grommet.

    2.2 Analysis of assembly process of ABS motor

    Assembly processes of ABS motor are made up of a number of 34 unit process; armature

    cleaning, o-ring insertion, grommet silicon application, housing and grommet insertion, brush

    insertion, spring insertion to brush holder, rotor bearing insertion, silicon application and yoke

    assembly, and packing, etc.

    They can be combined into of 15 processes like Table 1 grease application, magnet holderassembly, holder insertion to yoke pig tail control, air supply, bolting of yoke, magnetization of

    magnet and airtight test, etc. For instance, grease application is that gets a grease or o-ring by

    injector. The important control factors of this process are number of o-ring, amount of grease

    application and check whether the grease application is done to all o-ring uniformly.

    Yoke

    Subassembly

    Armature

    Subassembly

    GrommetSubassembly

    HousingSubassembly

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    Table 1. Assembly process ABS motor

    Fig. 2 shows operation sketch and main control items of grease application, air supply, o-ring

    insertion process of operation number 1.

    Fig. 2 Sketch and control factors of no.1 work

    Important control factors of grease application are number of o-ring, amount of grease

    application, whether the grease application is done all o-ring uniformly and location of o-ring,

    etc. Important control factors of air supply and o-ring insertion are exterior view of commy and

    shaft, whether the grease application is done to o-ring and location of o-ring, etc.

    No. Assembly process Time

    1Grease application, Air supply,O-ring insertion

    15

    2 Magnet holder assembly 12

    3 Holder insertion to yoke 8

    4 Bearing insertion to yoke 85 Armature and Bearing insertion 156 Pig tail control, Air supply 10

    7 Silicone application, yoke insertion 148 Grommet insertion 28

    9 Bolting of brush holder 1010 Bolting of yoke 10

    11 Spring insertion to brush holder 3412 Magnetization of magnet 15

    13 Aging ~ Load test 1614 Airtight test 15

    15 Sticker sticking, rust preventing, packing 16

    InjectorGrease

    Vinyl-bag

    O-ring(100ea)

    O-ringArmature

    Jig

    Grease application Air supply, O-ring insertion

    Important control factors

    Exterior view of Commy

    Exterior view of Shaft

    Whether the grease

    application is done to O-ring

    Location of O-ring

    Number of O-ring

    Amount ofgrease application

    Whether the grease

    application is done to all

    O-ring uniformly

    Location of O-ring

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    8 Implementation and Line Balancing of Assembly Line of ABS Motorfor Improvement of Assembly Productivity

    Fig. 3 Determination of automatic and manual assembly

    3 Implementation of assembly line of ABS motor

    3.1 Determination of Automation possibility of assembly processautomation

    According to geometrical characteristics of products and degree of complexity of assembly

    process, it can be determined whether the assembly processes can be automated or not(Fig.3).Because manual assembly can be performed very easily, we don t have to waste unnecessary

    investment cost, if it is very difficult process to perform by automatic assembly.

    There are some influencing factors to determine automatic or manual assembly like a

    production volume, cycle time and investment cost, etc. Manual assembly is performed, if part

    characteristics are weak in transporting, arrangement, feeding, joining area. In this research, we

    analyze assembly process and object that is used in the process to determine automatic or

    manual assembly. If a part is difficult to be assembled automatically at the four areas,

    transporting, arrangement, feeding, joining, it is assembled manually.

    In this research, automatic assembly and manual assembly are determined by considering of

    assembly process and part characteristic. In the aspect of part characteristic, it distinguishes theweak parts from others that satisfy with precondition of transporting, arrangement, feeding and

    joining for automatic assembly. Therefore the part is determined manual assembly. The others

    that satisfy with preconditions of process are decided automation probability in terms of

    assembly possibility. The processes that don t satisfy with assembly possibility are performed

    by manual assembly. The processes that satisfy with assembly possibility determine equipment

    of automatic assembly. And the processes that are determined by manual assembly are

    determined the method of transporting, arrangement, feeding and joining.

    Table. 2 shows that example of the grease application process that applies for number of 4 area;

    transporting, arrangement, feeding, joining. Transporting area can be divided into T1(Possible

    continuous transporting), T2(Available transporting), T3(No tangling in transporting) and

    Determination factors of product

    l Geometric characteristics

    l Design for assembly

    lMarket life

    Area of consideration

    l Transporting area

    l Arrangement area

    l Feeding area

    l Joining area

    Influencing factors

    l Production volume

    l Tact time

    l Investment cost

    l Utilization of labor

    Determination factors of process

    l Degree of complex of process

    l Assembly task characteristics

    l Connecting relation between

    assembly processes

    Automaticassembly

    Manualassembly

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    Table 2. Automation possibility of grease application

    T4(Available workpiece carrier). Arrangement area is divided A1(Possible continuous

    arrangement), A2(Possible arrangement minimal controlling), A3(Available arrangement

    device) and A4(No tangling in arrangement). Feeding area is divided F1(Possible continuous

    feeding), F2(laying stability after feeding), F3(Available feeding device) and F4(Possible grasp

    in feeding). Joining area is divided J1(Possible simple assembly method), J2(Easy grasp),

    J3(Possible automation assembly) and J4(No additional adjustment or easy additional

    adjustment after joining). For example, the score of 1 of T1 that is one of standards for

    transporting in transporting area means that we can get information for automation possibility of

    grease application harder.

    Table 2 shows a calculation method and result of grease application process. The evaluation

    criteria of each area are extracted to calculate a point of automation possibility, and degree of

    possibility can be obtained. For instance, in this process, automatic transporting of parts is most

    difficult compared with other area, and the total point of automation possibility is -12 . Using

    this method the automation possibility of all process is determined, and they are compared to

    decide an automation priority.

    3.2 Determination of assembly equipment of assembly process

    After determination of automation possibility of each assembly process, we determine the

    method and machine of transporting, arrangement, feeding. Assembly machines and equipments

    are determined on only process that is performed by automation assembly. Assembly machine

    equipment is determined by characteristics of process.

    Therefore, this research is consisted of three numbers of for ABS motor assembly; armature

    bearing placing m/c, holder yoke placing m/c, motor tester m/c. Armature bearing placing m/c is

    performed assembly of yoke subassembly, brush and check of bolt height and assembly of

    armature and bearing insertion. Hold yoke placing m/c is performed insertion of yoke and

    magnet hold subassembly. Meter Tester m/c is performed aging, S/F check, check of shaft

    Determination of automation possibility ofeach area functional factor

    Criteria Degree Criteria DegreeT1 -1 A1 -1

    T2 -1 A2 +1T3 -2 A3 -1T4 -1 A4 -2

    Transpo

    rting

    Sum -5 Arrangement

    Sum -3F1 0 J1 +1F2 +1 J2 -1F3 -1 J3 0

    F4 -2 J4 -1Feeding

    Sum -2Joining

    Sum -1-2: very difficult

    -1: difficult0:same +1:easy

    +2:very easy

    Totalpoint

    -12

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    10 Implementation and Line Balancing of Assembly Line of ABS Motorfor Improvement of Assembly Productivity

    length, bolt, voltage, turning direction check, load check, etc. Fig.4 shows the assembly process

    that is accomplished by the placing M/C of armaturebearing and motor tester M/C. For instance,

    the assembly process joining of bearing and yoke, check of bolt height and brush, fixing of

    brush and joining of armature and bearing are performed by placing M/C of armature and

    bearing.

    Fig. 5 Working position of placing M/C

    Fig. 5 shows the all assembly position of assembly of assembly work in placing m/c of

    Armature bearing. It carries out this assembly on revolving 4 indexing table. That is, Position 1

    is the place of joining of bearing and yoke subassembly, it is checked of the bolt height and

    brush at position 2, position 3 is fixing of brush and position 4 is joining of armature and

    JigBearing

    Housing Ass y

    Armature

    Joining of bearing

    and yoke

    Check of bolt

    height and brush

    Cheker

    of bolt

    Jig

    Brush

    checker

    Fixing of brush

    Brush

    contact jig Clamp

    Joining of armature

    and bearing

    Placing M/C of

    armature, bearing

    Motor

    Load

    checker

    AgingCheck of shaft

    length, bolt

    Voltage, turning

    direction check

    Turning

    direction:CW

    Motor

    Load check

    Checker

    of boltheight

    Eccentricity checkerMotor tester M/C

    Fig. 4 Assembly processes by placing M/C and tester M/C

    Position 2

    1000mm

    450 550

    550

    1200

    Position1

    Load/unload

    Position 3

    Position 4

    Checker

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    BK21LogisticsTeam, July2000 11

    bearing place. Fig. 6 shows assembly work in holder yoke placing m/c. That is, it shows sketch

    and work position of magnet and holder subassembly and yoke insertion. After insertion of

    magnet holder subassembly or bearing into jig of placing m/c, it puts yoke at proper position,

    operate device insertion and finish insertion.

    Fig. 6 Assembly processes of holder yoke placing M/C

    3.3 Layout of assembly machinery equipment

    The basic objective of machinery equipment and facility layout in assembly system is to

    improve a assembly productivity and the detail objectives are a to be the smooth inner

    transporting, efficient place utilization, consideration of safe of machinery and equipment, and

    creation of safe and comfortable inner circumstance for worker, etc.

    The necessary of information and data that are needed to plan and determine of equipment

    placement are production capacity, form of production and process, machinery equipment and

    plants, inner system and amount of transporting, amount of work of each position and form and

    size of plants. There are several equipment layouts; product layout(line layout), process layout,

    fixed position layout.

    In this research, we use two layouts; first, we used efficient and prompt product layout

    because we product one special item of ABS motor. Second, we used mixed layout that also

    used process layout , which has test equipments in one place because most of test processes

    need when a product is finished. Actually, there are coexistence forms of different layout,

    though we distinguished these three layout forms strictly in the above. The required space to

    assembly lines of ABS motor is 3920mm, 57300mm. In this space, it is impossible and

    inefficient that equipments like a straight line is determined.

    So, we choose U-line like Fig. 7 in order to efficient rationing and flexible production. The

    advantages of U-line improve line balancing and work efficiency with minimizing of the size of

    Joining of magnet

    holder and yoke

    Joining of yoke and

    bearing

    Holder YokePlacing M/C

    Yoke

    Magnet

    Holder

    Assy

    Yoke

    Bearing

    Position 1

    Position 2

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    12 Implementation and Line Balancing of Assembly Line of ABS Motorfor Improvement of Assembly Productivity

    space used and movement distance of worker in a coexistence of manual and automation line.

    See the Fig.7 below, the network that is left side figure shows related and adjoined forms

    simultaneously considering between machinery equipments and assembly sequence. And then,

    we determined U-line like right side of this figure with modification of this network. A solid

    line indicates that it can reduce transporting distance and cost when it adjoins each other. A

    point solid line indicates a little relation when we consider layout or layout modification.

    Fig. 7 Activity relation graph and line type of motor three layout forms strictly.

    3.4 Work assignment and line balancing

    In assembly line balancing, we have to adjust the required work time of each work place to

    assembly and manufacturing work with making almost same extent of production period. This

    line balancing has been studied as Heuristic approach though it has been studied mathematical

    proofs. That is, it is a kind of technique that we expect good plan, we can t assure that it is the

    best thought. Some techniques well known of heuristic approach are Kilbridge-wester, ranked

    positional weight heuristic, etc.

    In this research, we apply three types assembly line balancing. There are Kilbridge-wester

    method, standard work assignment method and improved heuristic method. Improved heuristic

    method allocates their work shares through 7 levels below.

    Level 1 Grasp the target value of cycle time and limitation of priority constraints.

    Level 2 Determine positional weight of each work

    Level 3 Put a ranking in order of high PW of each work

    Level 4 Put a ranking in priority succession process order of each work (If there are same rates,

    9

    2

    3

    4

    10

    12

    13

    14

    15

    1

    5

    8

    11

    6

    7

    432

    6

    7

    10

    12

    14

    13

    15

    1

    5

    9

    8

    11

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    BK21LogisticsTeam, July2000 13

    choose a work which has big Task time)

    Level 5 Combine level 3 and 4. And output total rank about each work

    Level 6 Allocate each work to work place in posteriority TR order.

    Level 7 Select a method that can minimize slack time in each work place.

    Fig.6 shows the result of assembly line allocation of each work through assembly line balancing

    of ABS motor with three methods above. Cycle time is division assembly time by assembly

    yield and the assembly time per a unit.

    For example, using a standard work task table, if we intend to produce 15,000 outputs per a

    month, which has 22days, the output will be 682, and a standard for working hours is 10 hours

    25 min, that is 36099 sec, so the cycle time which is divided work time by work output is 54sec.

    Therefore, if we want to 682 outputs, we should produce one motor per 54sec. And next, we

    determined the number of workers by considering of net assembly time of machine and

    handling time of worker. Generally, working time is handling time itself. But, this assembly line

    contains assembly time of machinery as well as handling time of subassembly. `

    The line efficiency of equation (3.2) and smoothness Index of equation (3.3) are used to indicateefficiency of assembly line balancing

    In these formulas, K means the number of workers, CT is a cycle time, N is assembly

    process, Ti is a working hours of each worker, and Tmax is the maximum working hours of

    each worker

    Productionvolume

    5000 units/month 10000 units/month 15000 units/month

    Heuristic Worker Assigned process Sec Worker Assigned process Sec Worker Assigned process Sec

    1 9,8,11,13,14,15 119 1 11,13,14,15 81 1 11,12 49

    2 8,9,7,10,12 77 2 8,9,10 482

    5,1,2,3,4,6,7,

    10,12107

    3 1,5,2,3,4,6 68 3 13,14,15 47

    4 5,6,7 39

    5 1,2,3,4 43

    Standard

    workassignment

    method CT=162sec, LE=93.3%, SI=12 CT=81sec, LE=91.4%, SI=13.6

    CT=54sec, LE=90.6%, SI=11.5*

    1 11,8,2 74 1 11,1 491

    11,8,2,1,3,9,4,7,6 154 2 1,3,9,5,4,7,6 80 2 8,2,3 48

    2 10,12,13,14,15 72 3 10,12,13,14,15 72 3 9,5,4,7 47

    4 10,12,13 41

    5 6,14,15 41

    Improvedheuristic

    methodCT=162sec, LE=72.1%, SI=82 CT=81sec, LE=92.5%*, SI=10*

    CT=54sec, LE=90.6%, SI=11.5*

    1 11,8,2 74 1 11,1 491

    11,8,2,1,3,9,4,7,6

    1542 1,3,9,5,4,7,6 80 2 8,9,5 53

    2 10,12,13,14,15 72 3 10,12,13,14 ,15 72 3 2,3,4,7,6 52

    4 10,12,13 41

    5 14,15 31

    Kilbridge-wester

    methodCT=162sec, LE=72.1%, SI=82 CT=81sec, LE=92.5%*, SI=10*

    CT=54sec, LE=83.4%, SI=25.4

    5542221

    ==

    =

    =

    CTTK

    N

    i

    i (3.1)

    Table 3. Assembly processes by placing M/C and tester

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    14 Implementation and Line Balancing of Assembly Line of ABS Motorfor Improvement of Assembly Productivity

    %6.90%100))((

    1

    =

    = =

    CTKTLE

    N

    i

    i (3.2)

    Fig. 8 Alternative of assembly line by line balancing

    The indices are used when it is compared that assembly line balancing and work allocation of

    more than one. Line efficiency is good value if its value is high, and bad value if its value is low.

    If value of smoothness index is low, line balancing improves than value of smoothness index is

    high.

    In Table 3, line efficiency and smoothness index, which are calculated by standard work

    assignment method, are resulted as good value when it produce 5000 motors per month. But

    relatively, improved heuristic method is given as bad value because this value is only dependent

    on cycle time. Therefore, when motor is produced number of 5000, it is best way to allocate by

    using the table of standard work assignment, and then experientially repeating trade-off, that is,

    assignment value of workstation in this table. Both of improved heuristic method and Kilbriede-

    wester method can be proposed as appropriate heuristic method in case of number of 10,000.

    And standard work assignment method and improved heuristic method can be proposed as

    appropriate heuristic method in case of number of 15,000, both heuristic methods are show in as

    the same results, 90.6% of line efficiency and 11.5% of smoothness index. Though two heuristic

    methods have a same value of LE and SI as shown in Table. 3, they have a little difference of

    types and number of assembly task that are allocated to the worker.

    As shown in Fig. 8, in case of number of 10,000 per month, U-line can be considered as

    improved heuristic method and Kilbriede-wester method considering optimal work allocation,

    transporting pass of work, type of work and work sequence. As shown in Fig. 8, in case of

    15,000 per month, U-line cab be considered as standard work allocation method, optimal work

    allocation, transporting pass of work, type of work and work sequence.

    5.11)(1

    max == =

    N

    i

    iTTSI (3.3)

    Production vol. 15000 /month

    CT 54 sec No. of worker 5CT 81 sec No. of worker 3

    Production vol. 10000 /month

    Sticker,packing

    Airtight

    test

    Aging

    Load

    checker

    Magnetization

    ofma net

    BoltingSilicone

    application,yoke

    Pig tailcontrol,

    air supply

    Bearing

    and yokeassembler

    Holder

    and yoke

    assembler

    Magnet

    and holder

    assembler

    Spring

    insertion to

    brush holder

    Grommet

    insertion

    Hbolting

    RotorAnd

    bearing

    assembler

    Air supply,O- ring

    insertion,grease

    12

    3

    Sticker,

    packing

    Airtight

    test

    Aging

    Load

    checker

    Magnetization

    ofma net

    BoltingSilicone

    application,

    oke

    Pig tail

    control,air supply

    Bearingand yokeassembler

    Holder

    and yokeassembler

    Magnet

    and holderassembler

    Spring

    insertion tobrush holder

    Grommetinsertion

    H

    bolting

    RotorAnd

    bearingassembler

    Air supply,O-ring

    insertion,

    grease

    5

    4

    2

    13

    Production vol. 15000 /month

    CT 54 sec No. of worker 5CT 81 sec No. of worker 3

    Production vol. 10000 /month

    Sticker,packing

    Airtight

    test

    Aging

    Load

    checker

    Magnetization

    ofma net

    BoltingSilicone

    application,yoke

    Pig tailcontrol,

    air supply

    Bearing

    and yokeassembler

    Holder

    and yoke

    assembler

    Magnet

    and holder

    assembler

    Spring

    insertion to

    brush holder

    Grommet

    insertion

    Hbolting

    RotorAnd

    bearing

    assembler

    Air supply,O- ring

    insertion,grease

    12

    3

    Sticker,

    packing

    Airtight

    test

    Aging

    Load

    checker

    Magnetization

    ofma net

    BoltingSilicone

    application,

    oke

    Pig tail

    control,air supply

    Bearingand yokeassembler

    Holder

    and yokeassembler

    Magnet

    and holderassembler

    Spring

    insertion tobrush holder

    Grommetinsertion

    H

    bolting

    RotorAnd

    bearingassembler

    Air supply,O-ring

    insertion,

    grease

    5

    4

    2

    13

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    BK21LogisticsTeam, July2000 15

    Table 4. Work allocation of each worker

    If the target product volume is number of 10,000, the cycle time is 81second. And in this time, 3

    workers are needed for one motor production. If the target product volume is number of 15,000,

    cycle time is 54second. And in this time, 5 workers are needed for one motor production.

    Table 4 shows an allocating process of worker, work time and movement distance. W is worker,

    S is work sequence, P is allocated process and D is movement distance. The number of

    allocated process, assembly time and movement distance of each work is different. But total

    assembly time and movement distance can be adjusted uniformly by line balancing. Like

    automation assembly, in case of automatic assembly and manual assembly is mixed, its total

    work time of each work has to similar through line balancing. Specially, movement distance has

    to be considered. Because movement distance of figure shows the case of when one motor is

    produced. If the number of motor is many, movement distance can be different.

    Therefore, it has to accomplish work exchange per time and work reallocation through

    determination of movement distance of each work and degree of work fatigue, etc.

    Production volume: 10,000units/monthW S P T D W S P T D

    1 11 34 2.3 6 7 14 0.7

    2 8 28 0.8 7 6 10 0.83 2 12 0.7

    2

    Sum 80 5.31

    Sum 74 3.8 1 10 10 3.71 1 15 1.0 2 12 15 0.7

    2 3 8 0.7 3 13 16 0.63 9 10 0.7 4 14 15 1.2

    4 5 15 0.8 5 15 16 0.5

    2

    5 4 8 0.6

    3

    Sum 72 6.7

    Production volume: 15,000units/monthW S P T D W S P T D

    1 1 15 1.3 1 8 28 0.82 2 12 0.6 2 9 10 1.0

    3 3 8 0.4 3 10 10 1.04 4 8 1.2

    3

    Sum 48 3.8

    1

    Sum 43 3.5 1 11 34 1.21 5 15 1.2 2 12 15 1.2

    2 6 10 0.8

    4

    Sum 49 2.43 7 14 1.0 1 13 16 2.0

    2

    Sum 39 3.0 2 14 15 0.73 15 16 0.8

    Unit: time-sec., distance-m

    5

    Sum 47 3.5

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    16 Implementation and Line Balancing of Assembly Line of ABS Motorfor Improvement of Assembly Productivity

    4 Conclusion

    In this research, we implemented a assembly system of final assembly process of automobile

    ABS motor. There are 4 subassemblies of ABS motor; yoke, housing, grommet, and armature.

    But we can't automate these completely because of their geometric and assembly process

    characteristics and some considerations of assembly cost, required place, etc.

    So, we constructed mixing form of automation assembly and manual assembly. First, we

    established assembly order with grasp of assembly process. Second, we classified the whole

    assembly process into each unit and decided the automation possibility of each process. In

    manual assembly, we decided methods of transporting, arrangement, feeding and joining, and in

    automation assembly, we determined machinery equipment according to assembly mechanism.

    And we also make U-line layout for efficient arrangement of assembly equipment that is

    decided by unit process.

    It helps to minimize time of worker's movement and assembly. Finally, we allocated assembly

    work of each worker by realizing assembly line balancing after deciding the number of workers

    who can produce the target yield. And we estimated the efficiency of constructed assembly line

    with the index of line estimation like as line efficiency and leveling inde x.

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    5 Reference

    Boothroyd, G., 1991, Assembly Automation and Product Design, Marcel Dekker, Inc., 1991,

    pp.181-208.

    Elsayed A., Thomas O., 1994, Analysis and Control of Production System, Prentice Hall, pp.

    344-402.

    Francis, R. L., McGinnis, L. F. and White, J. A., 1992, Facility Layout and Location: An

    Analytical Approach, Prentice Hall, pp.27-184.

    Frank J., 1996, Assembly Automation, Industrial Press Inc., pp. 47-77.

    Lotter, B., 1989, Manufacturing Assembly Handbook, Butterworths, pp.303-383.

    Redford, A. and Chal, J., 1994, Design for Assembly, McGraw-Hill, Inc., pp. 75-134.

    Rosari, L. M., 1989, Design for Assembly Analysis: Extraction of Geometric Features from a

    CAD System Data Base, Annals of the CIRP, vol. 38, No. 1, pp. 13-16h

    Schmidt, L. C. and Jackman, J., 1995, Evaluating Assembly Sequences for Automatic Assembly

    Systems, IIE Transactions, 27. pp.23-31.

    Thomas E., 1991, William L., and Clay W., Manufacturing Planning and Control System,

    IRWIN, pp. 120-154.


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