Job #: 75068 Author name: DeLit Title of book: Integrated Design of a Product Family ISBN number: 1402074379 Integrated design of a product family and its assembly system INTEGRATED DESIGN OF A PRODUCT FAMILY AND ITS ASSEMBLY SYSTEM PIERRE DE LIT Universite libre de Bruxelles, CAD/CAM Department, 50 av F D Roosevelt, CP165/14, 1050 Brussels, Belgium ALAIN DELCHAMBRE Universite libre de Bruxelles, CAD/CAM Department, 50 av F D Roosevelt, CP165/14, 1050 Brussels, Belgium Springer Science+Business Media, LLC Library of Congress Cataloging-in-Publication Data De Lit, Pierre, 1973Integrated design of a produet family and its assembly system / Pierre De Lit, Alain Delchambre p.em ISBN 978-1-4613-5066-8 ISBN 978-1-4615-0417-7 (eBook) DOI 10.1007/978-1-4615-0417-7 Engineering design Manufaeturing proeesses Delchambre, A II Title TA174.D4522003 607.42'7 de21 2003046112 Copyright © 2003 Springer Science+Business Media New York Originally published by Kluwer Academic Publishers in 2003 Softcover reprint of the hardcover 1st edition 2003 AlI rights reserved No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, microfilming, recording, or otherwise, without the written permission from the Publisher, with the exception of any material supplied specifically for the purpose of being entered and executed on a computer system, for exclusive use by the purchaser of the work Permis sion for books published in Europe: permissions@wkap.nl Permissions for books published in the United States of America: permissions@wkap.eom Printed an acid-free paper Contents INTRODUCTION Assembly 1.1 1.2 1.3 What is assembly? Assembly methods Assembly operations 1 2 Assembly lines Principle 2.1 2.2 Line models 6 Product and assembly line design 3.1 Design decomposition 3.2 Influences and interactions 8 10 Scope of the book 11 One typical case study Disposition 13 15 STATE OF THE ART PF and assembly line design 1.1 1.2 Design methodologies Integrated design approaches PF representation 2.1 Terminology 2.2 PF structure Discussion 2.3 Design for assembly 3.1 Qualitative ana lyses 3.2 Quantitative analyses 19 19 19 20 29 29 32 45 48 48 48 DESIGN OF A PRODUCT FAMILY AND ITS ASSEMBLY SYSTEM VI 3.3 3.4 DFA in integrated product and line design Discussion 51 55 Ap representations 4.1 Preliminary definitions 4.2 Liaison- or command-based representations 4.3 Component- and subset- based representations 4.4 Discussion 69 Assembly planning 5.1 Quick browse 5.2 PG generation 5.3 Proposing SAS 71 71 72 79 Line design 6.1 Line design methods and algorithms 6.2 MHE selection 80 80 82 PF AND ASSEMBLY LINE DESIGN METHODOLOGY 85 57 58 58 63 Concurrent engineering and assembly 85 Concurrent design and "optimisation" problems 2.1 Industrial, multi-objective problems and optimisation 2.2 Solution stability and iterative procedures 2.3 Concurrent development and design sensitivity 2.4 Design choices and solution space pruning 2.5 Preliminary conclusions 87 88 89 90 92 94 Proposed design philosophy for PFs and assembly lines 3.1 Main principles 3.2 PF structuring, DFA and preliminary AP 3.3 Assembly technique and mode selection, detailed AP 3.4 Line layout 94 95 95 98 101 Conclusions 103 DESCRIPTION OF PRODUCT FAMILIES Proposed PF structure representation 1.1 Preliminary definitions 1.2 Generic and variant elements 1.3 Decomposition of a PF into FEns 1.4 Links between the FEns 1.5 Description of a FEn 1.6 Description of the GCS 1.7 Description of the generic links 105 105 105 109 III 117 118 118 120 Contents VII 1.8 1.9 1.10 Graphical representations FEns and design teams Synthesis of the model 121 122 122 Illustrative case study 2.1 Early design 2.2 Intermediate design 2.3 Detailed design 123 123 124 126 Conclusions 128 PF STRUCTURING AND PRELIMINARY DFA 129 Objectives of the OFA 129 Proposed structuring and preliminary OFA issues 2.1 How to obtain variations in the subfunctions of a PF? 2.2 Issues for VGCs, oocs and pseudo-varying links 2.3 PF structuring and standardisation 2.4 Preliminary OFA rules Summary of the approach 2.5 130 131 133 135 140 142 Case stud y 3.1 Before the appl ication of the OFA 3.2 Application of the OFA 144 144 Conclusions 148 REPRESENTATION OF APS FOR PFS 146 151 Proposed AP representation 151 Examples 153 Conclusions 155 PRELIMINARY ASSEMBLY PLANNING 157 I Hypotheses on the APS 157 Proposed preliminary AP tool 2.1 Ar methodology 2.2 Constraints in the AP generation 2.3 Dealing with PCs 2.4 Determination of potential base parts 2.5 Proposing GSAS 2.6 Constructing the PGs for FEns 2.7 Merging the APS of FEns into APs for the PF 2.8 Ap evaluation criteria 158 158 Case study 159 160 164 168 170 183 189 193 viii DES IGN OF A PRODUCT FAMILY AND ITS ASSEMBLY SYSTEM 3.1 3.2 3.3 Ap at early design stage Ap after the prel iminary desig n of MagSyst and Box Ap after the pre limi nary desig n for the PF Co ncl usions DETAILED DFA AND AP I A detailed DFA principle for PFS: sta ndardisation Joi ning process and assembly met hod se lection Deta iled AP of the FEns Modification of the ge neric liaison graph Mo dificat ion of the AP of the FEns Ar- and DFA: releasing PCs Modification of the AP for the PF From a PG between GCS to a PG between operations 3.1 3.2 3.3 3.4 3.5 Eq uipment preselection 4.1 Decomposing the operations 4.2 Se lecti ng the eq uipment Fina lisi ng the PF design and the AP 4.3 Case study Desig n not challenging preliminary res ults 5.1 5.2 Design q uestioni ng for mer resu lts 5.3 Co mparison Conclusions LINE LAYOUT I Line decomposition 1.1 Team-oriented as sembly 1.2 Defining and linking workcentres De termination of the conveyi ng system 2.1 Co nveyor selection in the proposed methodo logy Se lection methodology 2.2 MHE typo logy and evaluation criteria 2.3 2.4 Examples Logical layou t 3.1 Essentia ls on the LB and RP approaches 3.2 W ho le thing in a nut she ll Differences between log ical and physical layou t Case st udy 193 194 195 196 199 199 200 201 201 203 208 209 212 212 212 216 21 218 218 221 223 224 225 226 226 226 228 229 229 229 232 234 235 240 241 244 Contents IX 5.1 5.2 Old design New design Conclusions 244 245 246 I Summary of the results and discussion 249 249 Further research 254 10 CONCLUSIONS AND FURTHER WORK Appendices Appendix A Precedence operators I Operator ::s Operator -