PROJEKTIRANJE I OBLIKOVANJE

SUSTAVA MONTAŽE
PROJEKTOWANIE I FORMOWANIE
SYSTEMÓW MONTAŻOWYCH
PLANNING AND DESIGN OF ASSEMBLY
SYSTEMS
 Lectures  ZORAN K U N I C A
zkunica@fsb.hr

LO DZ , 15th and 16th of March 2016

CONTENT

1. What is assembly and where it takes place?

2. Basic terms and features of assembly
3. Product structure (hierarchy)
4. DFA  Design For Assembly
5. Assembly process
6. Planning of manual assembly
7. Organisational forms of manual assembly

2
 Literature
G. Boothroyd, P. Dewhurst, W. Knight: Product Design for Manufacture and
Assembly, CRC Press, 2011.
G. Boothroyd: Assembly Automation and Product Design, Marcel Dekker, New
York, 1991.
J. A. Speck: Mechanical Fastening, Joining, and Assembly, Marcel Dekker, New
York, 1997.
B. Vranješ, B. Jerbić, Z. Kunica: 2.14 Montaža, Inženjerski priručnik, Školska knjiga,
Zagreb (in print, in Croatian)
B. Jerbić, G. Nikolić, B. Vranješ, Z. Kunica: Projektiranje automatskih montažnih
sustava, Kigen, Zagreb, 2009. (in Croatian)
W. Stadler: Analytical Robotics and Mechatronics, McGraw-Hill, New York, 1995.
http://titan.fsb.hr/~zkunica/conf/MOTSP2010%20Kunica%20Invited_Lecture.pps
Internet (equipmet and software manufacturers, catalogs and CAD models)
Standards: ISO, EN

http://titan.fsb.hr/~zkunica/nastava/Assem http://www.youtub
e.com/watch?v=Z-
bly_LODZ_Kunica.pdf BbpaNXbxg

3
 1. What is assembly and where it takes place?
PRODUCTS often consist of more PARTS, that are previously MANUFACTURED
in different times and places, thus they must be ASSEMBLED.
Assembly (its parts: handling and joining) exists in very different areas of
human work.

Existing production processes –

range that covers all eras of
human history – from manual to
completely automatised work.
4
maintenance (dissasembly
and assembly)

5
6
 The Ford Flathead Assembly Line In 1946

SUBSTITUTION OF HUMAN WORK

(mehanisation and automation)?

Charles C. Ebbets - Lunch atop a

Skyscraper (construction of Rockefeller
centre in New York, 1932)
7
 automatic
handling at
quality
control
operation

team-work of robots (Romeo

and Julia), cca 1995

high-speed automatic system

220 parts per minute
16 different parts (in two
years)
8
 Substitution of human work in packing Two-arm robot

http://titan.fsb.hr/~zkunica/nastava/v/Airline Tray Kitting

http://titan.fsb.hr/~zkunica/nastava/v/Mot
divx.avi oman+SDA10+robot+assembly.flv

Folds a Shirt (Baxter Robot)

Fold a Shirt in less than 2 Seconds! https://www.youtube.com/watch?v=Mr7U9p
https://www.youtube.com/watch?v=kIDUDhpjhqo Qtwq8
9
 Bernard M. Snyder

ARTEFACT − PRODUCT (value of use and market value)?

PRODUCTION QUANTITIES?
DEDICATED (SPECIALISED) OR FLEXIBLE?
ECONOMIC LABOUR/WORK DIVISION (humans and/or
machines)!
10
 PRODUCT AND PROFIT?

BRAND CATWALK SHOPS IN INDIA

11
12
AUTOMOTIVE INDUSTRY – LEADING INDUSTRY IN AUTOMATION

Final assembly is not a part of it!

cca 1915 today

http://titan.fsb.hr/~zkunica/nasta
va/v/Production+of+the+2008+R
enault+Laguna.flv
13
Leading countries in industrial robotics (2010):
1. class – Germany, Japan, South Korea;
2. class – Sweden, Finland, Italia, Slovenia, Taiwan, USA. 14
Automotive industry – leading industry in
automation. 15
The small number of robots in general industry points to
its significant potential, and a trend that is being
increasingly recognised: the penetration of automation in
the areas of smaller production quantities i.e. products
for which the automation of their production almost until
recently was considered impossible. 16
 2. Basic terms and features of assembly

Assembly is any activity which aims to connect two or more objects into a
whole, with specific purpose.
Assembly is present in all human activities, from industry (construction,
mechanical engineering, electronics, shipbuilding ...), to households. In
industry, the production process regularly ends with assembly.
Components for assembly are: (individual) parts, assemblies and amorphous
(formless) substances.
Parts are forms that have defined geometry, and are manufactured from one
piece of material.
Assemblies are forms that have defined geometry, and are composed of at
least two components.
Formless (amorphous) substances are: gases, liquids, powders and granules.
Relationships between components are realised by joining (mounting,
fastening etc.) techniques.
Often, final assembly is a product.
17
18
19
20
Assembly cannot be avoided in the following cases:
a) when a function (purpose) of a product cannot be achieved with single
part
b) movable parts in a product
c) different materials of parts
d) cheaper manufacturing of two parts of simple geometry, instead of one
of more complex geometry
e) to ensure interchangeability (maintenance), transportation and
dismantling for cost reducing
f) special requirements for the product (aesthetic, for example).

21
 Aims Results

COMPANY
Assembly in a production system
(structure, flow of materials and
information)

Since assembly appears as

the final activity in the
Market

Market
production, all the omissions,
Purchase Production Sales mistakes and shortcomings
of previous stages of
production are accumulated
Accounting & monitoring in it.
PRODUCTION
R&D Production planning

Production managemant
Raw
materials PRODUCTION Products

Assembly,
Forming Machining
testing

22
The degree of complexity of the assembly, depending on the product (whose
dimensions range from miniature electronic products to tankers), leads to
various assembly forms (kinds of assembly system).

Just diversity of products appearances and their characteristics (small/large

volumes, weight and number of components, complex geometric shapes...),
and the fact that the automation of assembly faces a particularly complex
issue of replacing human labour, based on an exceptional motoric, sensoric
and mental abilities, cause that assembyl is still performed most often by
hand, using simple tools.

Therefore, the relative share of employees in assembly is high, ranging in

particular branches of economy between 17 and 34 %.

23
 A healthy, well-fed worker for 8 hours can maintain an average of 75 W output
power.

Power during
pedaling

http://www.ohio.edu/mechanical/programming/hpv/hpv.html
24
The
anatomy of
the human
hand and
systemati-
sation of
ways to
grasp an
object

http://www.mech.ut
ah.edu/senior_desig
n/07/uploads/Roboti
cHand/HuHaStrbyF
orceandMoment.pdf

25
 34
The relative share of employees in assembly [%]

35

30
24,4 23,2
25
19,1 20,22
20 17,6

15

10

0
mechanical vehicles electrical precision production of office
engineering production engineering engineering, tools, other machinery,
watches, optics metal goods computers

The share of employees in the assembly by branches of industry

26
Gap between the degree of automation in manufacturing and assembly, has
caused a significant increase in the time and cost of assembly share in the
realisation of product.
The average assembly share of time in the cycle of production is from 40 to 60
%, and in cost up to 50 %.
100%
90%
80%
70%
Assembly
Cost estimate
60%
share: and time-share
50% by cost installation in
40% by time
30%
total
20% production
10% costs
0%
engines for heavy electrical appliances
vehicles

Therefore, the assembly automation appears as a technological imperative,

and today represents an area of strategic reserves of profits for
manufacturers (Investment? Wages?).
27
28
29
 WHY HAS ASSEMBLY LONG BEEN NEGLECTED?
Assembly started to be intensively studied in the 70s and 80s of the last century. Advances
and achievements in technologies of parts fabrication, naturally, shifted focus to assembly.
Here are the reasons of systematic neglecting of assembly:
• Manufacturing of parts is carried out cost-effectively by equipment that exceeds human
capabilites and capacity, while in assembly the situation is reversed.
• As long as there was a problem of parts manufacturing, assembly problem did not exist.
• People are efficient in the assembly, because they have sensory, motoric and mental
capabilities, superior to those of machines. (Everything is possible to automate, but it is the question of
price.)

• People have an instinctive ability to connect objects to each other, thus sometimes
assembyl was not considered as serious technology, for which specific rules should have
been defined that could lead to the increased efficiency of assembly.
Assembly is an activity that make people feel pleasure. People are acquainted with assembly from an early age. The most successful
toys are based on the natural tendency of people to assembly (Lego, puzzles, ...). It should be noted that infantile assembly and
satisfaction that arise from successful performance, implies disassembly, too. Disassembly and assembly are physical and motoric
realisations of instinctive and trained fundamental thought processes of knowing, analysis and synthesis, which occur very early, so
some people even forget that in their older age (One colleague in class regarding product structuring said: „We did that when we were
two or three (years)."). Valentino Braitenberg says that we tend to overestimate the complexity of the operation and structure of some
phenomenon, until we do not put it into parts.

• Assembly is regularly inexpensive. The necessary investment for manual assembly is

minimal, and the main cost is the costs of human labour. While that cost is small, there
is no motivation to improve the efficiency of assembly.
30
As a number of components of complex geometry rise, the complexity of
assembly process and its planning and management increases.

The solution used in the assembly of a specific product only rarely can be
used for other, different products.

Assembly may be realised on the same micro-location with manufacturing

system. However, in order to reduce costs of labour and/or transport,
assembly systems dislocate in areas of low workforce cost or close to
market (globalisation, local incentives, outsourcing, contract manufacturers,
no-name, OEM and „OEM” manufacturers).

Human labour vs machine work

Considering the automation of a process inevitably means to compare the
price of human labour and the cost of investing in automated equipment.
But, essentially, it is a price comparison of human physical labour and cost of
human labour that is embedded in the realised product  automatic
equipment (although the latter human labour eventually, gradually, by
automation, becomes smaller and smaller).
31
3. Product structure

The structuring of the product is the first step in

the design of assembly process and system.
Pieter Brueghel Older:
From the viewpoint of assembly, products are divided as follows. Tower of Babilon, 1563

BREAKDOWN BY : PRODUCTS

NUMBER OF COMPONENTS ONE-PIECE ASSEMBLED

NUMBER OF ASSEMBLY LEVELS ONE-LEVEL MULTI-LEVEL

One-level products are assembled in a single step, and mult-level in several

steps.

32
One-level product have no assemblies.

Product

Assembly

D  parts
KS  bought assemblies
BT  amorphous substances

One-level product

33
 Level of assembly
Level of product
Final assembly

Level of
subassemblies
Assembly of
subassemblies
ASSEMBLY

Level of
own parts

Level of
bought parts,
materials and
formless
substances

Multi-level product 34
The product structure describes the arrangement of the components and
their relationships in the product.
It is used to define the depth of the division of products, the possible
number of (sub)assemblies and their mutual hierarchical dependence.

Structuring the product, or assigning parts, assemblies and amorphous

substances to certain structural/hierarhical levels, is possible according to
different criteria.

Criteria of structuring can be:

• the existence of a (joint) between components (contact surfaces and edges)
• function, to allow (sub)assembly testing (for example, automobile motor)
• avoiding dissasembly
• economy
• sustainability (stability, non-separability) of (sub)assembly, especially during
transport (movement) from one assembly station to another
• (current) disposition (availability) of components.
35
The structuring of the product is the first step in the design of assembly
process and system.

Summary on structuring :
• The structuring of the product is the first step in the design of assembly
process and system, but moreover, it is assumed in each activity of product
realisation (including product design).
• In structuring, the special attention is paid to the possibility of the
formation of (sub)assemblies  GOAL of structuring.
• The PURPOSE of structuring is to obtain division of work (labour) 
assembly processes that are independent regarding time and space 
ensuring profit maximisation and shortening of the production cycle.
• In structuring, an emphasis may be given to functional features of the
product (especially at complex products), or a principle form of a future
assembly process and system.
• Structuring is related to assembly sequence and vice-versa, but they are
not the same!
36
The structure of the product may be shown by:
• graphics – graphs and trees
• matrix, and
• tables  Bills Of Materials (BOMs).
tree of structure (DIN 6789)

37
The structure of
the product P1
shown by a tree
and some possible
forms of future
assembly process
and system: a)
complete product
assembly in single
workstation, b)
assigning of
assembly work to
more workstations

38
 The structures of the products P1 and P2 shown by the matrix

Components (Sub)assemblies Parts

USAGE S1 S2 S3 S4 S5 D1 D2 D3 D4 D5 D6 D7 D8 D9
P1 1 3 1 4 1 12 6 3 1 2
P2 1 2 1 1 1 4 2 1 2 4 1 2
S1 2 1 2 1 8 4 2 1 2
S2 4 2 1
S3 1 2
S4 2 1 2 4 1 2
S5 1 2

39
Worksheet for table presentation of product′s structure: „structural BOM”
http://www.fsb.hr/~zkunica/nastava/Strktsas.doc

40
 Example: Coffee mill machine

It will be taken that the "lower part"

of the mill, the assembly A, is already
assembled (bought), so it is needed
to structure the remaining parts,
positions: 1-5 and 21. Positions 2 and
4 are connected to the assembly A by
thread.

Various kinds of product′s structure

are presented on the next page.

Can parts, positions 1, 3 and 5, form

their own assembly?

41
42
4. DFA  Design For Assembly www.dfma.com

The authors: G. Boothroyd and P. Dewhurst. Published in 1980 in the USA.

The purpose of the method:

Reducing cost of assembly, with the increase of quality and shorten the
time of realisation of product on market.

The objectives of the method:

1. minimising the number of components,
2. ensuring easy assembly of other components.

The method includes:

1. estimation of time and cost of assembly
2. quantification of product design efficiency − different designs of the
same products can be compared by quantification.

43
CONCEPT DFA − component of:
OF DFMA  CE (Concurrent
PRODUCT
Engineering)
 Integrated Product
Development
CAD
 PLM (Product Lifecycle
Management).

PROTOTYPE

PRODUCTION

44
DFMA (Design For
Manufacture and Assembly)

DFX

45
Results of 88 studies

46
1. stage Selection of assembly method and system

2. stage Product analysis Product analysis for Product analysis

for manual high-speed for robot
assembly automatic assembly assembly

3. stage Product re-design and new analysis

Stages of DFA method

47
 Manual
assembly
systems

High-speed
automatic
assembly
systems

Programmable
automatic
assembly
systems

48
Chart 1
SELECTION
OF ASSEMBLY
METHOD
AND SYSTEM

49
 Codes and variables in Chart 1
low cost medium cost high cost

Within the Chart 1, the numbers in italic in parentheses indicate the number of note (valid
for all charts).
NP – number of different products that will be assembled the first three years by basically
the same assembly system
NT – the total number of parts of products including those for the formation of variants
NA – the number of parts in the product
ND – number of parts in a product that will change their design in the first three years
RI – investment potential/ability of company, RI = SH x QE / WA (5)
SH – number of shifts
QE – company investment funds, to replace a worker in the assembly, in a single shift, USD
WA – annual price for a worker in the assembly, including overhead costs, USD
VS – annual production volume per shift, in millions
MA – manual system
MM – manual mechanised system
AI – single-purpose automatic system, synchronous
AF – single-purpose automatic system, asynchronous
AP – programmable automatic system
AR – programmable automatic system, robot (not listed in the Chart 1) 50
Notes on Chart 1

51
EXAMPLE

52
1. step: Calculate RI

RI = SH · QE / WA

SH = 2
QE = 40 kUSD
WA = 20 kUSD

RI = 2 · 40 / 20

RI = 4

Additional example:
QE = 10, WA = 1;
QE = 100, WA = 10.
RI = ?
53
2. step: Select row in Chart 1


VS = 0,5 (500 000 product/shift)
ROW 3
NA = 35

54
3. step: Select column in Chart 1

Additional information:
– market life of the product – longer than three years,
– parts are not of low quality,
– there is no need for manual operation.

If one of criteria above is not met: columns 8 and 9 – manual assembly.


NT = 45, NA = 35, ND = 10
COLUMN 1
RI = 4

55
4. step: Solution

row 3 and column 1

FIELD 31

AP SYSTEM,
low cost

Analysis for automatic assembly in the next step of DFA method!

56
 5. step: Discussion of the solution – variants

structuriring of product into subassemblies (NA = 15)

FIELD 41  AI system, low cost
FIELD 45  AP system, medium cost

higher volumes (VS > 0,65)

FIELD 01  AF system, low cost

lower QE  decrease of the RI

FIELD 32  MM system, medium cost

57
 PRODUCT ANALYSIS FOR MANUAL ASSEMBLY

Goals:
 decision on part elimination or integration
 estimation of handling and insertion time and cost.

1. step: Getting information on product

 technical documenation
 sample
 prototype
 CAD model

58
EXAMPLE of product DFA
analysis for manual
assembly  Pneumatic
piston sub-assembly

59
2. step: Assignment of identification numbers

 disassemble the product, or imagine what it would be like

 for each component assign an identification number, in
order of disassembly, starting from number 1
 (sub)assemblies of product should initially be treated as
parts and then separately analysed

60
 3. step: Filling the worksheet

 assemble the product, one-by-one, starting with the component with the
largest identification number
 fill a single row of the worksheet for each component

 data in worksheet
 Chart 2-1 and Chart 2-2

61
62
63
64
Chart 2-1 -- complete

65
Chart 2-1 1/3

66
Chart 2-1 2/3

67
Chart 2-1 3/3

68
69
Chart 2-2 -- complete

70
Chart 2-2 1/3

71
Chart 2-2 2/3

72
Chart 2-2 3/3

73
 • 9th column – criteria on component separability:

1. Is a component movable to already assembled components?

2. Should a componet be made of different materials, or isolated, from
the already assembled components?
3. Does a componet allow assembly or disassembly of previously
assembled components?

If the answer to all three questions is "no", enter zero in the 9th column.

If the answer to at least one question is "yes", in the 9th column, enter
"1„ or larger, taking into account the value that is listed in the second
column.

74
4. step: Calculation of aggregate values

When assembling of the product is finished:

 sum the values of the seventh column – assembly time, TM
 sum the values of the eighth column – assembly cost, CM
 sum the value of the 9th column – theoretical minimum
number of componnets, NM.

75
5. step: Calculation of (product design) efficiency (assemblability) for
manual assembly

EM = f x NM / TM

where:
NM – theoretically minimum number of components
TM – time of assembly, s
f = 3 s = const. – An ideal time to assembly a component, with easy
handling and insertion, and one-third immediately secured parts
after insertion.

EM = 3 x 4 / 40,25 = 0,29  29 %

76
NOTES

1. Handling of two components at the same time - time reduction of

1/3.
2. The case when components are not in crowd and stochastically
oriented, but in magazines and pallets (ordered state as a
component presentation method).

77
 RE-DESIGN OF A PRODUCT AND NEW ANALYSIS

1. step: Consideration of actual and minimal number od components

 if the number in the 9th column is less than that in the second column,
examine the possibility of component elimination
 Controversies: cost of manufacture, lack of equipment, standardisation and
approvals, resistance within the company.

2. step: Considerations of times of handling and insertion

 observe long times in 4th and 6th column

 examine the possibility of shortening the time by redesigning the
components, use charts 2-1 and 2-2 as a guide to critical features and
their improvement

78
EXAMPLE of product DFA
analysis for manual
assembly  Re-designed
Pneumatic piston sub-
assembly

79
80
5. Assembly process
Assembly process consists of functions that are allocated to
equipment and workstations as operations.

Those functions, or operations, are (DIN 8593):

• insertion (joining, fastening...)
• handling
• testing
• adjusting
• special functions (heat treatment, packing, painting, deburring...)

Transition from abstraction to realisation, from idea to physical

event:
PRODUCT  PROCESS  SYSTEM.

On importance and risk of phantasy  Slavoj Žižek: The

Pervert's Guide to Cinema
81
Simple joining: a − basic part, b − part being inserted
Connection: function-principal technical solution 82
VDI 2860

Systematisation of functions  symbols of functions

Grouping of functions/symbols  principal technical solutions (catalogs)
Grouping of principal technical solutions  devices and equipment
Grouping of devices and equipment  automatic system

83
http://www.hro.ipa.fraunhofer.de/content/dam/agp/de/documents/Lehre/Skripte/Automatisierung/7_HH_Stand_20101214_cc_tcm101-175757.pdf 84
Examples of symbols Example of device
85
6. Planning of PLAN
DEFINIRANJE
AssemblyREDOSLIJEDA
sequence ASSEMBLY
manual assembly SKLAPANJA
MONTAŽE
PLAN
Elements ELEMENATA
DEFINIRANJE of work (tools,
RADA
crteži,
PRODUCT
PROIZVOD fixtures)
(alati, naprave)
blueprints,
sample, prototype,
sastavnice
BOMs uzorak, prototip, CAD model
CAD model
ODREĐIVANJE
Duration VREMENA
of elements of work
(MTM, WF)
strukturna
structural PRIKAZ I STRUKTURIRANJE
PRODUCT STRUCTURING
BOM
sastavnica PROIZVODA ZA MONTAŽU
FOR ASSEMBLY
IZRADAPrecedence
GRAFA PRETHODNOSTI
graph

DF(M)A
DODJELA
AssigningELEMENATA
elements of RADA
work
to workplaces
RADNIM MJESTIMA

Correction ofELEMENATA
KOREKCIJE elements ofRADA
work

OBLIKOVANJE MONTAŽNOGA
DESIGN OF ASSEMBLY
SUSTAVA
SYSTEM

plan montaže,
IZRADA RADNE DOKUMENTACIJE
Work documentation upute za montažu
IZVEDBA
Assembly
SKLAPANJA
execution
86
 Code of element
of work
Duration of
element of work
Precedence graph

Precedence graph in software,

such as Catia/Delmia and Siemens
NX (Tecnomatix)
87
Precedence graph  a basis for assignment of elements of work to
workstations, using several methods, such as: Ranking of positional values,
Field of capacity.

Both of methods above include estimation of number of workstations and

cycle time (taktzeit).
Cycle time:
c = T/N s/product
T  available time, s
N  number of products.

Sum of time of all elements of work assigned to a particular

workstation cannot be longer than cycle time:

 tk  c .
k Qi
88
 n [product/day]
240

180

120

60

2 4 6 8
t [minute/product]

Line

Carre

Examples of assigning of elements of

work to workstations and workstation
arrangement 89
 n [product/day]
240

180

120

60

2 4 6 8
t [minute/product]

Example of assigning of elements of work to workstations 

complete product assembly in a single workstation 90
 n [product/day]
240

180
160
120

60

2 4 6 8 t [minute/product]

L-shaped layout of
workstations

Example of
assigning of line
elements of work
to workstations
and workstation
arrangement
91
 Combinations of assigning of
elements of work for four
workstations

3 m
Z 2 f or m  4.
4
92
7. Organisational forms of manual assembly

1. complete product assembly in a single

workstation
2. assembly of large objects
3. movable workstations and fixed objects of
assembly
4. line assembly
5. movable workstations and movable objects of
assembly
6. assembly in autonomous groups

93
http://www.bosch.us/conte
nt/language1/downloads/
Bosch_MaE_delivery_spe
cs_appen42_Workplace_
Measurements.pdf

94
Assembly of
large objects

95
The Boeing Everett
Factory - 747

Čkalov, Novosibirsk

96
97
Boeing 777
Jetliners,
since 2006:
line for final
assembly,
movement
40,6
mm/minute

98
Project Scania – eM-Plant (Tecnomatix)
99
http://www.automationworld.com/factory-automation/flexible-assembly-line
100
 Some diploma works
at FSB

Filip Strsoglavec, 2011

Domagoj Jezl, 2010
Matija Petranović,
2011

101