automated assembly facility design tinisha mcmillion et-494 spring 2014 advisor: dr. roy bonnette...
TRANSCRIPT
Automated Assembly Facility Design
Tinisha McMillion
ET-494 Spring 2014
Advisor: Dr. Roy Bonnette
Instructor: Dr. Cris Koutsougeras
OVERVIEW
Design an Automated Assembly for DELL model M-UVDEL1 Mouse.
Process Design.
Line Processes.
Automation and Transportation Systems.
Automated Systems Layout.
3-D Modeling of Select Components.
Facility Design and Layout.
Production.
SPECIFICS
Process Design.
Disassemble Mouse.
Record placement and order of assembly.
Multiple variations considered.
High level process created.
3 lines – main board, bottom cover, top cover.
High Level Process
Individual Line Processes.
Components for each line determined.
Permanent Attachment Method Determined.
Snapping together.
Screw attachment.
Soldering.
Time trials completed.
18 second maximum.
23 second advancement speed determined.
Begin Board Assembly Position Memory Chip Right and Left Selection Switches Positioned
LED Light Sensing Assembly Positioned
USB Base Positioned Scroll Wheel Switch Positioned
Scroll Wheel Sensing Assembly Positioned
End Board Assembly
Solder Memory Chip to Board
Solder Selection Switches to Board
LED light soldered to Board USB Base soldered to Board
Scroll Wheel Soldered to Board Scroll Wheel Sensor Soldered to Board
Board Assembly Line
Begin Bottom Cover Assembly
Optic Plate Attached Board Positioned USB Cord Plugged into USB Base
Scroll Wheel and Spring Placed into Position
End Bottom Cover Assembly
Board Attached with Assembly Screws
Bottom Cover Assembly Line
Begin Top Cover Assembly Weight Positioned Grey Right and Left Selection buttons Attached
End Top Cover AssemblyWeight Attached with Assembly Screw
Begin Final Assembly Top & Bottom Covers Snapped Together by
Worker
Top Cover Attached to Bottom Cover with Assembly Screw
Three Slides and Serial Number Tag Attached to the
Bottom Cover
Mouse Assembly Complete
Top Cover Assembly Line and Final Assembly Process
Time TrialsAction Trial Number
AVG SECONDS
1 2 3 4 5 6 7 8 9 10
Solder Memory Chip 18
Solder Selection Switches 6
Solder LED Light 2
Solder USB Base 5
Solder Scroll Wheel Switch 2
Solder Scroll Wheel Sensing Assembly 3
Snap Optic Plate In Place 3 2 1 1 1 1 1 1 1 1 1.3
Position Board 3 3 2 3 4 4 3 2 2 4 3
Attach Board With Screws 7 10 8 5 7 10 7 6.5 6.5 6 7.3
Plug USB Cord Into Base 6 8 9 6 7 6 5.5 5 5 5.5 6.3
Scroll Wheel And Springs Assembled And Placed 12 14 15 12 11 10 13 13 12 14 12.6
Position Weight 2 3 4 2 2 2 2 2 2 2 2.3
Attach Weight With Screw 1 2 2 2 4 3 3 4 5 4 3
Right And Left Selection Buttons Positioned And Attached 4 6 5 4 4 4 4 4 4 4 4.3
Snap Top And Bottom Covers Together 10 12 13 11 12 13 10 11 11 10 11.3
Top And Bottom Cover Attached With Screw 3 6 5 4 5 4 5 4 6 3 4.5
Equipment Transportation.
Dorner precision move 2200 series conveyor system.
Machine integration.
Timed conveying.
Accurate part positioning.
Robotic pick and place.
Belt 6” wide, cleat height 1.5”
Robotics UNIX 700-H
Soldering processes.
48.5 pounds.
Floor mounted.
3’ x 5’ operating area.
5 programmable axes.
36 units required.
FANUC M1-iA-1H
Pick & place and screw attachment.
26.5 pounds.
Floor mounted.
2’ x 4’ operating area.
3 programmable axes.
96 units required.
3-D Modeling
Board and cradle.
1/8” gap included for soldering joints.
Bottom cover and cradle.
Rubber inlay created for stability.
Board and Cradle
Board
Cradle for Board
Bottom Cover and Cradle
Bottom Cover
Cradle for Bottom Cover
Automated Systems Layout
Robotics size and space requirements.
Flow of materials.
Personnel movement.
5’ allowed for preventative maintenance.
2’ x 2’ Return bins.
2’ x 3’ Material bins.
4’ x 4’ Inspection stations.
6’ x 6’ Manual assembly stations.
Complete Assembly Line
Facility Design 6 complete assembly lines.
Office space at 150’x91’.
Break rooms at 30’x50’ and rest rooms at 10’x20’.
Maintenance room at 30’x50’.
Shipping and receiving storage at 50’x100’.
Shipping and receiving area at 110’x60’.
Employee/visitor parking
60 – 9’x20’ standard spots for medium sized cars.
6 – 12’x20’ handicapped spaces with additional 5’x20’ area.
Standard 26’ spacing around rows.
Overnight truck parking.
Roads offset 50’, 25’ standard set back.
Facility Layout
6 Complete Lines
Office Space
Rest Rooms and 2nd Break Room
Maintenance Room
Shipping and Receiving Areas
Employee & Visitor Parking
Receiving Flow
Shipping Flow
Production Rates
Production Goal of 500,000 per year
1 unit per minute.
Material handling, packaging, inventory control, storage, shipping & receiving.
90% efficiency, 2% failure rate* and 3 hours a week for PM on 5 lines.
489,500 units per year which was insufficient.
80% efficiency, 2% failure rate* and 3 hours a week for PM on 6 lines.
522,000 unit per year.
Robotics and facility are not maxed out allowing for future expansion.
*Failure rate attributed to irregular parts, non-functional parts, assembly damage and inspection failures.
RESOURCES & REFERENCES
Dr. Roy Bonnette
Jonathan Newsom
James Stutts
Dorner Mfg. Corp.
FANUC
JAPAN UNIX
Questions?