Semi-automatic craft sites with Poka-Yoke principle

Scope

Turnkey delivery;

• Inventory required functions versus layout and manpower
• Process description per tool with detailed order handling
• Modify and re-configure existing tooling (combine functions)
• For new features and / or optimizations tooling design
• Concept, technical design, construction and commission

Purpose

Benefit for client;

• Relatively low engineering costs and quick response time on request.
• High degree of reliability proven, so quality-enhancing and risk-reducing.
• No need for expensive and risky supply equipment.
• Short R.O.I. By reuse tooling and principles

Conventional implementation

Advantage of conventional execution

• Lean production facility as compared to relatively large series, just what is strictly necessary.
• Relatively low production costs (installation can be determined at work).

Modular version (“Smartline”)

Advantage of flexible modular design

• Customize wide-use production facility for relatively small series, tooling and layout as needed without special tools and always rebuild.
• Reuse and / or expansion relatively simple.

Goal

Semi-automatic one piece flow assembly line of pump pads and cylinders for hydraulic systems for cabrios and cab tilting systems of trucks. Also the possibility of reuse and feasibility with regard to the number of different products.

Issue

Integration of human activity in semi-automated production environments without adversely affecting quality. Also ensure complete control of each assembly step, with the aim of ensuring the operation of the entire product as well. Testing not only the final product, often difficult Limited accessibility, but each step (indirect final check). The major challenge lies in the combination of the average number of operators on the line, the number of steps (functions) of the assembly and the required cycle times of this separate tooling. This means an optimal degree of automation per tooling and which features should all be included in one tool. In addition, a certain degree of flexibility must be taken for the purpose of assembling different types of pump blocks and cylinders without the need for completely new lines.

Approach

We basically use previously used tooling, provided it is a comparable function. Because the products have different variations in size and functions, the tooling will be tailored to this and, if necessary, completely brand new. Due to all cycling times per function i.c.m. Mapping associated tooling, we are able to make informed choices for the entire layout and find a good balance in the manpower on the line. Because each tool describes the entire assembly process, we can check each step through various detection / measurement systems and local security measures in the tool. We make optimal use of human ability (eye-hand coordination) to avoid complicated and very costly mechanization without compromising human failure. We also eliminate such monotonous and boring work as the motivation benefits.