A rapid analysis method for production line design

Abstract

Many highly accurate computer tools have been developed for production line design, such as simulation of assembly processes and virtual reality techniques, but these tools require much input information and are generally utilized only in detailed design stages. This paper proposes a rapid analysis method for manual assembly line design, which can be utilized in the conceptual design stage. This method is based on a layout tool with which design engineers can construct assembly line models using 2- and 3-D views, and then employ design evaluation techniques for numerous important criteria such as volume flexibility, and visibility, using the layout data. Spatial evaluation and quantitative efficiency analyses can be simultaneously performed, which enhance collaborative decision-making in the conceptual design stage. This method is applied to an assembly line design for an automobile air-conditioner part as a case study, illustrating the efficiency of utilization in the conceptual design stage that the proposed method provides.

Keywords:

• Rapid analysis
• Production line
• Conceptual design
• Manual assembly line
• Volume flexibility
• Collaborative design

Acknowledgements

This work was supported in part by the Environment for Cooperative Strategy Making in Manufacturing Enterprise (e-Com) project (Domestic project No. 0350) under a contract for Advanced Domestic Research, Development and Planning of the IMS (Intelligent Manufacturing Systems) International Joint Research Program. The authors especially wish to thank Mr Yura and Ms Fukutome at Shimizu Corporation for their help in constructing the Planning Table systems, and their important suggestions concerning production line design processes.