Flexibility in Assembly Planning Through Product Design in Industries
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Manufacturing processes and equipment that can handle preconceived and emergency changes with low penalty in time, effort, cost and performance are required in the industries to accelerate introduction of new product, handle breakdown of systems and modification of already existing products. Though there are several attempts on this research, especially in development of equipment capable of handling industrial changes but the results are still not satisfactory. Contributing to achieving a Flexible assembly system. Compensative flexibility Model/Approach was carried out in this research to handle Flexible Assembly system through product design. The model developed performed: generation of assembly sequence, schedule and balancing for assembly planning at the product design stage, extracted product assembles requirements for product design at the conceptual stage to guide the designer; synchronized assembly system and product design and; modularized assembly system and product design. Transportation system of an Assembly system of an engine was simulated using ProModel Simulator and the result was remarkable. Also the design of IC engine using two variance; inline and V IC engines showed remarkable improvement in parts interchangeability and commonality with modularized design; 76% of the parts used in inline engine were also used in the V engine variance. Results from simulation runs with 8 automatic guided vehicle (AGV) in the system were observed, with the average time spent by parts in the system and the average time blocked were significant dropped as number of buffers and AGV were increased; the effect was more pronounced with 8 AGVs and 8 storage buffers in the system. The average (AVG) time blocked with 8 AGV and 1 storage buffer was 56.7 minutes and reduced to 0 minutes when the number of storage buffer increased to 8 with 8 AVGs, the percent reduction was 100 percent while AVG time in the system with one storage buffer was 59.34 minutes and reduced to 4.37 minutes with 8 storage buffers which is 96.9 percent reduction. The variation of number of vehicles and buffers reduced or increased the time component spent in the system. Thus, if correct workstation or assembly system resources are determined and designs are modularised, more articles will be introduced to the market, time to market will reduce, many variances will be produced and there will be reduction in the cost of production. The application of this technique is recommended for processing industry.
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