sustainable assembly systems: ergonomic optimization of ... ergonomic optimization of volkswagen...

Sustainable Assembly Systems:

Ergonomic Optimization of Volkswagen

Commercial Vehicles Production a

@ Assembly Engineering Conference 2016

Uwe Hüter, Teamleiter Ergonomie, Volkswagen Nutzfahrzeuge Hannover

Dr. Lars Fritzsche, Fachbereichsleiter Ergonomie, imk automotive GmbH

24.02.2016 Seite 2

Contents

1. Challenges at Volkswagen Commercial Vehicles

2. General Procedure and Employee Participation

3. Implementation of Improvements

4. Ergonomic Design Process

5. Summary

Team Ergonomie, NP-HE/22

24.02.2016 Seite 3

Challenges at VW Commercial Vehicles Length and Height in Comparison to Passenger Cars

Crafter (max. 2,7 m)

T6 (max. 2,4 m)

Amarok

Golf 1,4 m

T6 max.

5,3 m

Amarok

T6

Golf 4,2 m

1 2 3 4

Crafter max. 6,9 m


24.02.2016 Seite 4

Challenges at VW Commercial Vehicles (1) Product Dimensions

• Product Dimensions:

Greater length and height of vehicles

More difficult accessibility

Increased proportion of overhead work

Parts are bigger in size and weight

More assembly tasks in car interior

• Product Lifecycle

• Plant Structures

1 2 3 4


24.02.2016 Seite 5

Challenges at VW Commercial Vehicles Part Dimensions

1 2 3 4

Wooden ground floor (ca. 20 kg) Paint auxiliary fittings


24.02.2016 Seite 6

Challenges at VW Commercial Vehicles (2) Product Life Cycle

• Produktdimensionen:

Höhe und Länge der Fahrzeuge

(dadurch) andere Zugänglichkeiten

höherer Anteil Überkopf-Arbeit

Größe und Gewicht der Bauteile

Höherer Anteil Innenraumtätigkeiten

1 2 3 4


• Product Dimensions :







• Plant Structures

24.02.2016 Seite 7

Challenges at VW Commercial Vehicles Product Lifecycle in Comparison to Passenger Cars

T6

2003 2015

1 2 3 4


24.02.2016 Seite 8

Challenges at VW Commercial Vehicles (3) Plant Structure

1 2 3 4


• Product Dimensions :







• Plant Structure

24.02.2016 Seite 9

Challenges at VW Commercial Vehicles Structure of Hannover Plant: NZM (New Sustainable Assembly)

1 2 3 4

BA4

BA

5

Finish ML

4

ML

14

ML

3

ML

13

Do

ors

Pre

ase

mb

ly

Step 3 SOP 01/2016

Step 2 SOP 2015

Step 1 SOP 2012/2013

Step 4 SOP 2016/2017

BA5 BA6 BA7


24.02.2016 Seite 10

Contents





5. Summary


24.02.2016 Seite 11

General Procedure at Hannover Plant Ergonomics as Part of the Plant Strategy

Volkswagen Production System Volkswagen „Fit for Future“ Programme

1 2 3 4


24.02.2016 Seite 12

1 2 3 4 General Procedure at Hannover Plant Employee Participation in „Review Teams“


• Review Teams consists of representatives

from different departments (Production,

Planning, I.E., HR, Unions, etc.)

• Common generation and assessment of

ideas for ergonomic improvements

• Systematic status tracking and continuous

reporting to plant management

24.02.2016 Seite 13

General Procedure at Hannover Plant Reporting and Escalation Levels

Improving ergonomics workplace design in 21 review teams

across the entire commercial vehicle production process

Step Activity Level Turnus

1 Cost center committee Section Manager Every 3 weeks

2 Ergonomics steering committee

(all shops, all activities)

Plant Manager Every 2 month

3 Live presentation of topics from

Body, Paint and Assembly shop

Board Member Every 6 weeks

(1 example)

Review Team

1 2 3 4


Press shop Body shop Paint shop Assembly Quality Contr. Logistics

24.02.2016 Seite 14

Contents





5. Summary


1. Work organization:

1.1 Workplace design (working height, platforms, racks, trolleys, etc.)

1.2 Process design (change of sequence, line balancing, optimization)

2. Technical improvements:

2.1 Lightweight stool

2.2 Raku seat

2.3 Tools & Fixtures

2.4 Manipulator & Balancer

2.5 Automatic Tools / Screwdrivers

2.6 Full Automation

3. Product design:

3.1 Parts & Design changes

incr

ea

sing

co

sts,

co

mp

lexi

ty , tim

ely

eff

ort

Implementation of Improvements Categories of Improvements

1 2 3 4

24.02.2016 Team Ergonomie, NP-HE/22 Seite 15

24.02.2016 Seite 16

Implementation of Improvements Definition of „Ergonomic improvement path“

0

20

40

60

80

100

120

140

160

Initial Situation 1.HY 2014 2. HY 2014 1.HY 2015 2.HY 2015 2016 20xx

Product

changes T7

x WP-design

x Stools

x Tools

x Manipulator

x Automation

x Part design

x WP-Design

x Tools

x Manipulator

x Automation x WP-Design

x Stools

x Tools

x Manipulator x WP-Design

x Tools

x Raku seat

x Manipulator x WP-Design

x Stools

x Manipulator

x Screwdriver

(dates and improvements are fictitious )

1 2 3 4


Work organisation

& technical measures

24.02.2016 Seite 17

1 2 3 4


Status quo

Status01/2013

Status02/2016

Status01/2013

Status02/2016

T6 Amarok

NZM 2017

T7

NZM 2018

NZM 2016

Example: Press shop (1) Roof frame

Before After

• 3 parts at a time (total weight > 3 kg)

• Ergonomically bad picking height

• Deep bending while placing

• 2 workers (left/right)

• Decoupling of worker from press cycle

time

• No manual load handling

• Packaging is now possible with one

worker

35 Pts. 12 Pts.

- 23 Pts.

1 2 3 4

24.02.2016 Seite 18 Team Ergonomie, NP-HE/22

Example: Body shop (2) Hood assembly und adjustment

Before After

• Hood fixture has to be liftet manually (7,5 kg)

• Red workplace for 8 workers

FOTO FOTO

72Pts. 35 Pts.

- 37 Pts.

• Fixture with gas spring. Lifting force < 30 N

• Strong reduction of assymetric shoulder strain

1 2 3 4


Example: Paint shop (3) Optimization glueing of interior rear view mirror

Before After

• Rework for glueing the interior mirror

• Deep bending, standing posture or crouching


• Sitting on lightweight stool

• Reduction of rework through optimization of the glueing station and workplace

1 2 3 4


Example: Assembly shop (4) EC-screwdriver for seat belts

Before After

FOTO FOTO

73 Pts. 48 Pts.

- 25 Pts.

1 2 3 4


• Screw seat belts with power screwdriver (pistol grip) and manually tightening with wrench

• Screws have to documented on data card

• Screws are tightend with the EC-screwdriver, no manual tightening and documentation

• Increased productivity, double handling avoided

Example: Assembly shop (5) Door preassembly

Before After

• Doors were fixed at the vehicle

• Ergonomic problems due to restricted acessibility in many assembly stations

• Doors are now seperated in a pre-assembly line,

and reassembled to the car later in the process

FOTO

1 2 3 4


Before After

• Stool placed in the vehicle, multiple pick & place actions with assymetric load handling (> 5 kg)


• Leightweight stool 2,5 Kg

• Reducction of manual load handling > 50%

• High acceptance by workers

FOTO FOTO

55 Pts. 48 Pts.

- 7 Pts.

Example: Assembly shop (7) Leightweight stool for interior tasks

1 2 3 4


24.02.2016 Seite 24

Contents





5. Summary


Product Engineering Production Planning Series Production

Ergonomic Product Design Ergonomic Work Design Ergonomic Assessment and

Continuous Improvement

Critical ergonomic work tasks from reference car

Optimizing ergonomically critical work

from PRODUCT point of view

Optimizing ergonomically critical work

from PROCESS point of view

Corrective

Ergonomics Prospective

Ergonomics

Ergonomic Design Process General (Future) Procedure

1 2 3 4


Summary

• Ergonomic challenges in commercial vehicles production due to

greater dimensions of body and parts and prolonged lifecycle

• Systematic approach is based on plant strategy and includes comprehensive risk assessment and status tracking

• Participation of employees (Review Teams) and reporting to plant

management (Escalation Levels) is key for success

• In future more efforts should be concentrated on prospective

ergonomic design at product and production process level


24.02.2016 Seite 27

(Video 90 s)


Ergonomie_Film_Layout_V05.mp4

Contact data:

Uwe Hüter

Team Manager Ergonomics

[email protected]

Tel.: +49-511-798-7237

Dr. Lars Fritzsche

Division Manager Ergonomics

[email protected]

Tel.: +49-162-2500-347

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