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A quality-driven assembly sequence planning and line configuration selection for non-ideal compliant structure assemblies
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Ceglarek, Dariusz, Franciosa, Pasquale, Shahi, Vahid Jandaghi and Masoumi, Abolfazl (2019) A quality-driven assembly sequence planning and line configuration selection for non-ideal compliant structure assemblies. The International Journal of Advanced Manufacturing Technology, 106 . pp. 15-30. doi:10.1007/s00170-019-04294-w
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Official URL: https://doi.org/10.1007/s00170-019-04294-w
Abstract
In automotive body assembly systems, an optimum assembly sequence planning (ASP) not only increases production efficiency and product quality, but also decreases cost and process cycle time. Typically, ASP evaluation approaches are focused on design for assembly criteria, and very few studies have considered the impact of ASP on dimensional accuracy. The major challenges involving quality-driven ASP evaluation can be enumerated into three categories: (1) batch of compliant non-ideal parts to consider real part defects; (2) variation propagation modeling in multi-station assembly (MSA) system in the presence of stochastic manufacturing errors both at product and process levels; and, (3) the development of dimensional quality criteria for quantitative ASP comparisons. This paper proposes a methodology based on the modeling of dimensional errors propagationin MSAwith a batch of compliant non-ideal partsto improveproduct dimensional quality through optimizing ASP and assembly line configuration. It entails three main steps: (i) assembly sequence generation by k-ary assembly operation method for a predetermined assembly line configuration; (ii) variation propagation simulation taking into account a batch of non-ideal parts, station-to-station repositioning errors, and spring-back phenomenon in MSA system; and,(iii) robust optimization of ASP based on developed quality criteria which contains two quantitative indices.The potential benefits of the proposed methodology are successfully demonstrated on automotive front-rail assembly process.
| Item Type: | Journal Article | ||||||
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| Subjects: | T Technology > TS Manufactures | ||||||
| Divisions: | Faculty of Science > WMG (Formerly the Warwick Manufacturing Group) | ||||||
| Journal or Publication Title: | The International Journal of Advanced Manufacturing Technology | ||||||
| Publisher: | Springer-Verlag | ||||||
| ISSN: | 0268-3768 | ||||||
| Official Date: | 2 October 2019 | ||||||
| Dates: |
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| Volume: | 106 | ||||||
| Page Range: | pp. 15-30 | ||||||
| DOI: | 10.1007/s00170-019-04294-w | ||||||
| Status: | Peer Reviewed | ||||||
| Publication Status: | Published | ||||||
| Access rights to Published version: | Restricted or Subscription Access | ||||||
| RIOXX Funder/Project Grant: |
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