Smart Automation - seven methods for final assembly

Monologues 7

Preface 9

Acknowledgements 10

Acronyms 11

1   Introduction 15

Reference management 17

Detailed user material 17

2   Design for automatic assembly (DFAA) 19

Background 19

Description 20

Analysis at product level 21

The Seven areas exemplified through the gearbox 21

Analysis at component level 25

Industry example: Improving the DFA index by redesigning components 30

Tips for further reading 31

3   Hierarchical task analysis (HTA) 33

Background 33

Applications 34

Description 34

Step 1: Determine the goal of the task 35

Step 2: Determine common target values 36

Step 3: Identify sources of information and select method for data collection 37

Step 4: Break down the goal into intermediate tasks 38

Step 5: Validate the division of the tasks 41

Step 6: Identify important operations 41

Step 7: Generate and test hypothesis 41

Industry example: Production line for painting 42

Tips for further reading 46

4   Competency matrix 47

Background 47

Applications 47

Description 48

Step 1: Document operations 48

Step 2: Document operators 49

Step 3: Rank operators based on experience and knowledge 49

Step 4: Rate operations on the basis of necessary knowledge levels (KSRK) 51

Tips for further reading 53

5   Information overview 55

Background 55

Applications 55

Description 56

Level 1: Information overview at operation level 56

Level 2: Information overview at system level 60

Tips for further reading 61

6   Design principles for information presentation (DFIP) 63

Background 63

Applications 63

Description 64

Step 1: Selecting operation where the information presentation is to be improved and breaking down the operation into tasks 65

Step 2: Identifying and supporting the cognitive processes in the tasks in the operation 66

Step 3: Analyzing the tasks based on how the operator perceives his or her environment 67

Step 4: Analyzing the tasks with regard to mental limitations 68

Step 5: Analyzing the tasks based on individual differences and preferences 70

Step 6: Analyzing the tasks regarding the location of content and information carriers 71

Tips for further reading 72

7   Complexity index (CXI) 75

Background 75

Applications 75

Description 76

Step 1: Choosing a station or area to be analyzed 76

Step 2: Distributing the questionnaire 76

Step 3: Analyzing questionnaire responses 77

Step 4: Proposing improvements 78

Industry example: Vehicle manufacturing 79

Tips for further reading 81

8   Dynamic automation strategies (DYNAMO++) 83

Background 83

Applications 83

Description 83

Phase 1: Analyzing the present situation 85

Phase 2: Measuring 86

Measuring physical automation 87

Measuring cognitive automation 88

Phase 3: Analysis 92

Phase 4: Implementation and follow-up 95

Tips for further reading 96

9   Automation strategy – a combination of different methods 97

Background 97

Industry example 1: Focus on quality 97

Industry example 2: Focus on cost 99

Tips for further reading 103

10 Automation 107

Background 107

Physical automation 109

New parameters to consider in assembly 4.0 112

Cognitive automation 114

Tips for further reading 117

11 Complexity 119

Background 119

The complex assembly 119

Objective complexity 121

Subjective complexity 122

Complexity elements 122

Tips for further reading 123

List of figures 125

References 127

Appendix 1 135

Appendix 2 137

Appendix 3 147

Appendix 4 149

Index 157