Assembly planning

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The term assembly planning summarizes methods for designing and structuring the processes of an assembly system and the assembly line . The aim is to achieve minimum assembly costs .

Assembly is the core business of many companies. Most of the value creation that takes place here should be optimally planned and not diminished by waste. The share of assembly in the total production time is around 20–50% in mechanical engineering and vehicle construction.

Taking into account the general conditions such as cycle time, number of pieces , new or reconstruction planning and other restrictions in the assembly process, assembly planning gives a comprehensive picture of the prevailing processes.

definition

The assembly activity is made up of the sub-tasks of joining, handling, checking, adjusting and special operations in accordance with DIN standards and VDI guidelines. During assembly , a product of higher complexity with predetermined functions is assembled in a certain time.

When planning and designing an assembly system for a specific product, the work content is systematically structured based on quantities, variants, required technologies and operating resources, as well as organizational and ergonomic criteria.

Mission and goal

Due to the strong competitive situation, companies have to cover increasingly large product ranges with small batch sizes and short life cycles while keeping production costs low in order to remain competitive. Assembly systems must therefore be based on the following criteria:

  • Flexibility: the system should be flexible with regard to product (types, quantities) and extensions (stations, lines, modifications)
  • Reusability and modularity: the system should consist of standardized parts to enable subsequent use
  • Late creation of variants: Use of standardized parts and modular principles
  • Quick achievement of the planned number of pieces: both when starting up and when converting production
  • Reduction of assembly costs: investments and personnel costs
  • Planning the supply and supply of parts: the supply logistics can become a bottleneck due to the large number of variants and requirements

Basic requirements for the assembly system, such as economy, ergonomics and energy efficiency, must be met. It becomes clear that the assembly planning includes not only the pure planning of the assembly process but also the planning of the entire assembly system including specific work steps and operating resources.

Approach for assembly planning

The assembly planning process runs iteratively. In the iteration loops, the planning and the required information become more and more detailed, the evaluation options increase and the planning is optimized.

Assembly planning phases. Own illustration based on Konold and Reger 2003, pp. 31–32

The assembly planning project is divided into a fixed structure independent of the product. The steps in the assembly planning process model are not to be followed sequentially. Parallel and repeated runs of the individual process steps result from the iterative approach. Within the planning process, there can always be feedback to other sub-processes, as the process steps often influence one another. (see figure process model).

First, planning premises and goals are defined. A decisive factor for the design of the assembly is the desired output (units / year) and the cycle time of the overall assembly system that can be determined from this . After the assembly sequence has been determined, equipment, quality criteria and their verification, as well as time and investment costs are planned. An assembly system with a station division is shown in a layout. The first solution concepts for special tools and systems are created. Planning can also be supported by 3D simulations and material flow simulations .

A first rough plan is detailed in the course of the project and converted into a detailed plan. Results are recorded in a specification, which also enables direct inquiries to suppliers of assembly systems. Furthermore, the phases of implementation and start-up support can be part of the assembly planning project.

literature

  • Bruno Lotter and Hans-Peter Wiendahl (2012): Assembly in industrial production. A manual for practical use . 2nd edition Berlin: Springer Vieweg. ISBN 978-3-642-29060-2
  • Peter Konold and Herbert Reger (2003): Practice of assembly technology. Product design, planning, system design. 2., revised. and exp. Edition Wiesbaden: Vieweg. ISBN 978-3-528-13843-1

Individual evidence

  1. ↑ Lotter, B .; Wiendahl H.-P. (Ed.): Assembly in industrial production. A guide for the practice. 2nd edition Berlin: Springer Vieweg, p. 3. ISBN 978-3-642-29060-2 .
  2. ↑ See: Joining (DIN 8593), Handling and Controlling (VDI 2860), Adjusting (DIN 8580), Lotter, B .; Wiendahl H.-P. (Ed.): Assembly in industrial production. A guide for the practice. 2nd edition Berlin: Springer Vieweg, p. 2. ISBN 978-3-642-29060-2 .
  3. ↑ Lotter, B .; Wiendahl H.-P. (Ed.): Assembly in industrial production. A guide for the practice. 2nd edition Berlin: Springer Vieweg, p. 1. ISBN 978-3-642-29060-2 .
  4. ↑ Konold, P .; Reger, H. (2003): Practice of assembly technology. Product design, planning, system design. 2., revised. and exp. Wiesbaden: Vieweg, p. 32. ISBN 978-3-528-13843-1
  5. ↑ Lotter, B .; Wiendahl H.-P. (Ed.): Assembly in industrial production. A guide for the practice. 2nd edition Berlin: Springer Vieweg, p. 4. ISBN 978-3-642-29060-2 .
  6. ↑ Deuse, J .; Busch, F .: Time management in assembly In: Bruno Lotter and Hans-Peter Wiendahl (eds.): Assembly in industrial production. A guide for the practice. 2nd edition Berlin: Springer Vieweg, p. 89. ISBN 978-3-528-13843-1 .
  7. ↑ Konold, P .; Reger, H. (2003): Practice of assembly technology. Product design, planning, system design. 2., revised. and exp. Wiesbaden: Vieweg, pp. 31–32. ISBN 978-3-528-13843-1
  8. ↑ Hartel, M .; Lotter, B .: Planning and evaluation of assembly systems In: Bruno Lotter and Hans-Peter Wiendahl (eds.): Assembly in industrial production. A guide for the practice. 2nd edition Berlin: Springer Vieweg, pp. 370–372. ISBN 978-3-528-13843-1 .

See also