IN
DEGREE PROJECT MECHANICAL ENGINEERING, SECOND CYCLE, 30 CREDITS
STOCKHOLM SWEDEN 2019 ,
Low rate automation in
manufacturing and assembly - A framework based om improved methods towards higher
automation level
A case study at AIRBUS HELICOPTERS ARGYRI SEIRA
KTH ROYAL INSTITUTE OF TECHNOLOGY
SCHOOL OF INDUSTRIAL ENGINEERING AND MANAGEMENT
URL: www.kth.se/en/itm
URL: www.kth.se/en/itm
“Happiness is the meaning and the purpose of life, the whole aim and end of human existence, one day machines will embark on the hard and iterative tasks so humans will have time to pursue it.”
Aristotle 384-322 BC
In memory of my father Christos
A BSTRACT
S AMMANFATTNING
v
A BSTRACT
S AMMANFATTNING
vi
vii
P REFACE
viii
ix
A CKNOWLEDGMENTS
x
TABLE OF CONTENTS
xi
1
L IST OF F IGURES
2
L IST OF T ABLES
3
4
2
Part I
Theoretical Procedure
3
1 I NTRODUCTION
The Investigated Industry – Low Rate Production
54%
21%
12%
10%
2%
1%
0% 10% 20% 30% 40% 50% 60%
Airbus Leonardo Bell Russian Helicopters Others Sikorsky
SALES
Sales
4
Problem Statement
4 5 15 17 27 29 33
121
162
0 50 100 150 200
H175 Dauphin Family
H160 Super Puma Family
H135 NH90 H130 H145 H125
Sales
Sales
5
Research questions, purpose and objective
•
•
•
•
•
Scope and delimitations
6
Approach and thesis outline
7
Research methodology
Theoretical Procedure
Introduction
Literature Review
Approach and Methods
Analysis & Results
Comparison Analysis and Final Conclusions
8
Empirical Collection and Analysis Theoritical
domain
Introduction
Literature Review
Definition of terms and
Variables
Approach and Methods
Personal inputs and modification of
the existed concepts
Set of relationships and variables
Process Analysis Concept development Generation of
Results
Evaluation
Specific Predictions and
factual claims
Discussion
Conclusions
9
Interviews and Hands-on training
Literature - Benchmark
Aerospace Automotive Helicopters
Other General
10
2 B ACKGROUND AND L ITERATURE R EVIEW
11
Helicopter Production
12
Composites Manufacturing
Major Components
Assembly
Final Assembly
Flight line
13
14
Theory and Industrial Automation Principles
2.2.1 Assembly Principle
•
•
15
•
•
2.2.2 Automation of the manufacturing processes
16
•
•
17 2.2.3 Design for Automated Assembly (DFA 2 )
2.2.4 Flexible Manufacturing Systems
18
19
2.2.5 Collaborative Robots
20
21 2.2.6 Automated Internal logistics
Current approach for automation analysis
2.3.1 Case study approach – basis of the procedure
22 2.3.2 Current Dynamo ++
Getting Started
•Research questions
•Priori constructs
Selecting Cases
•Specified Population
•Theory flexibility without build hypothesis
•Constrains extraneous variation and sharpens external flexibility
Crafting Instruments
and Protocols
•Multiple data collection
•Qualitative and quantitative data combined
•Multiple investigations
Entering the field
•Overlap data collection and analysisincluding field notes
•Flexible and opportunistic data collection methods
Analyzing Data
•Within-case analysis
•Cross-case pattern search using divergent techniques
Shaping Hypothesis
•Iterative tabulation of evidence for each construct
•Replication, not sampling, logic across cases
•Search evidence for "why" behind relationships
Enfolding Literature
•Comparison with conflicting literature
•Comparison with similar literature
Reaching Closure
•Theoritical saturation when possible
23
Future Stage New Current Stage
Pre study Measurement Analysis Implementation
Goal functions: Which processes can be automated?
How to change the LoA (benchmarking, case study to suppliers, market magnitute)
Triggers for change:
Totally manual operations, demand for better working efficiency
How does the production works today?
Current Stage
What is the LoA of each process today?
What is the
opportunity to invest on automation?
What is effected by the posible solutions?
2.3.2.1 Level of Automation
24
25
26
2.3.2.2 SoPI (LoA C ; LoA P )- Square Of Possible Solutions
𝑆𝑜𝑃𝐼 → (𝐿𝑜𝐴 𝑚𝑒𝑐 (𝑚𝑖𝑛; 𝑚𝑎𝑥)) ∧ (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (𝑚𝑖𝑛; max)) 𝑆𝑜𝑃𝐼 = (𝐿𝑜𝐴 𝑚𝑒𝑐 (𝑚𝑖𝑛; 𝑚𝑎𝑥)) ∗ (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (𝑚𝑖𝑛; max))
𝐿𝑜𝐴 𝑚𝑒𝑐ℎ (𝑦) = 1 ≤ 𝑚𝑖𝑛 ≤ 𝑚𝑎𝑥 ≤ 7 ∧ 𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 ( 𝑥 ) = 1 ≤ 𝑚𝑖𝑛 ≤ 𝑚𝑎𝑥 ≤ 7 𝑆𝑜𝑃𝐼 𝑡𝑎𝑠𝑘 ≤ 𝐿𝑜𝐴 𝑡𝑜𝑡𝑎𝑙
𝑆𝑜𝑃𝐼 𝑡𝑎𝑠𝑘 ∈ 𝐿𝑜𝐴 𝑡𝑜𝑡𝑎𝑙
27
Auxiliary Methods - Methodology that improves DYNAMO++
2.4.1 Axiomatic Design
28 Customer
Domain
Functional Domain
Physical Domain
Process
Domain
29 𝐴
[𝐹𝑅] = [𝐴][𝐷𝑃]
𝐴 𝐴 𝑖𝑗 = 𝜕𝐹𝑅 𝑖
𝜕𝐷𝑃 𝑗
[𝐷𝑃𝑠] = [𝐵][𝑃𝑉𝑠]
𝐵
30 2.4.2 Design Structure Matrix
→
𝐹𝑅1 𝐹𝑅2 𝐹𝑅3
→
•
Functional Domain
FR1 FR2 FR3
FR0
Physical Domain
DP1 DP2 DP3
DP0
31
•
•
2.4.3 Analytic Hierarchy Process (AHP)
Left Domain representing the
"what" as FR
FR1
FR11 FR12
FR13
FR2
FR21 FR22
Right Domain representing the
"how" as DP
DP1
DP11 DP12
DP2
32
D efi ne t he pr o blem
Determine the kind of knowledge sought
St ru ct u re a d eci sio n hier arch y
1) Goal 2) Objectives 3) Criteria 4) Set of alternatives
Pa irwi se com pa riso n
Each element in an upper level is used to compare the elements in the level immediately below with respect to it
W e ig ht the pr io rit ie s
Use the priorities obtained from the comparisons to weight the priorities in the intermediate below. Do this for every element.
Then for each
element in the
level below add
its weighted
values to obtain
global priority.
33
3 M ETHODOLOGIES
Introduction
Research Quality
34 𝑄 = 𝑅 × (𝑆 + 𝑃)
𝑄 𝑅
𝑆 𝑃
Approach
35 3.3.1 Case Study
Additional principles to the standard method
"Derive Results"
Methodology Study
Approach
Build theory from Case
Studies
Dynamo++
Current State
Future State
Axiomatic Design Market research (new
LoA & SoPI) Risk Assessment
Future Actions - Work Plan
Decision Making
Cost-Benefit Analysis Analytic Hierarchy
Process
36 3.3.2 Qualitative or quantitative approach
Course of action
{𝐿𝑅 𝑖𝑗 } × 𝐼 𝑘 = {𝑀 𝑘 } 𝐿𝑅 𝑖𝑗
Research questions - Specification of constructs
Areas of investigation - Cases Literature Review
Qualitative and Quantitative data (interviews, data archives, observations etc)
Data collection
Case analysis - "Process analysis"
Measuring "LoA"
"Future stage" how to change what has been analyzed
Evaluation - Comparison with conflicting
literature
37 𝐼 𝑘
𝑀 𝑘𝑖
3.4.1 Pre-study
38 3.4.2 Data collection
3.4.3 Automation and robotics
39
3.4.4 Analysis and Implementation
40 3.4.5 Comparison and conclusions
Choosing the Best alternative
41
The Design phases
42
•
•
Improved Dynamo++
Pre-Study Phase
•Select the areas of investigation
•Select the operations
•Meet the operations
•Production Flowcharts
•Quantitative data
•Define the "low rate"
Measuring
•No Hierarchical Task Analysis
•Measure the cognitive and mechanical levels of automation of
operations
•Identify the SoPI
Analysis
•Axiomatic Design
•New SoPI based on data collection
•Risk Assessment
Implementation
•Cost-benefit analysis
•Analytical Hierarchy
Process
43
Decision Yes Start
Choose Automation
Scenario
Explain
End No
Cost Benefit Analysis
AHP
Discuss the method
Market data, Interviews
Meetings
Literature Review
Scenario 1:
Current State Scenario 2:
Future State Architectural
Framework
Proposed Methodology
44 1. Current
State
3. Future Actions
4.
Comparison Analysis
2. Future
State
45 3.7.1 Current State
3.7.1.1 Level of Automation
•How to change?
•What are the risks?
•How to mitigate the risks?
•New opportunities?
•What are the benefits to invest in automation?
•What are the decision steps?
•What is the final proposal?
•What is the Level of Automation today?
•What are the potential improvements?
•What to automate?
•Triggers for change
Pre Study Measurement
Analysis
Implementation
1. Current State
3. Future Actions
4.
Comparison Analysis
2. Future
State
46 3.7.1.2 Process Modelling
3.7.1.3 Process Mapping Composites
Manufacturing a)Fibre placement b)Pre-forming
Joining
a)Measurement, shimming
b)Drilling, positioning, riveting
c)Surface activation, adhesive application, positioning
Painting a)Single parts b)Final painting of
modules (final structure)
Logistics a)Pick and Place b)Material handling
(intra-logistics, parts, helicopters)
Process step 1
Process step 2
Process step 3
Process
step 4
47 3.7.1.4 Process Description
3.7.2 Future State
1. Current State
3. Future Actions
4.
Comparison Analysis
2. Future
State
48 3.7.2.1 Possible Improvements
3.7.2.2 Axiomatic Design
Customer Domain
a
b
c
49
1 2 3 4 5 6 7
1 2 3 4 5 6 7
SoPI (x min ;x max ),(y min ;y max )
50 3.7.3 Future Actions – Work Plan
1. Current State
3. Future Actions
4.
Comparison Analysis
2. Future
State
51 Comparison Analysis
1. Current State
3. Future Actions
4.
Comparison Analysis
2. Future
State
52
Part II
Data Application to Methodology /
Results
53
4 C URRENT S TATE - T ODAY
Composite Manufacturing
1. Current State
3. Future Actions
4.
Comparison Analysis
2. Future State
As-Is Process
Process Flow
1. Composite Manufacturing
2. Assembly Operations
Process Analysis - LoA & SoPI
3. Painting Process 4. Intra-Logistics
54 Glass
Fibre 15min
Vacuum 30min
Apply 3 layers of
CFRP sheets 60min
Vacuum 30min
Apply 3 layers of
CFRPS sheets 60 min
Vacuum 30min
Apply 3 layers half the part + 3 on the residual 30min
Autoclave
55
•
•
Fabrication
Impregnating (Resin)
AFP
Autoclave
Weaving Impregnating
Cutting
Manual layup
Autoclave
Binder Application
Cuting
Pre-forming
Pre-form integration into mould Resin Transfer
Moulding Ultra-Sonic
Inspection
Vacuum Assisted Process Ultra-Sonic
Inspection
56
•
•
•
•
•
𝑆𝑜𝑃𝐼 → (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (1; 7)) ∧ (𝐿𝑜𝐴 𝑚𝑒𝑐 (1; 7)) 𝑆𝑜𝑃𝐼 = (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (1; 7)) ∗ (𝐿𝑜𝐴 𝑚𝑒𝑐 (1; 7)) = 49
1 2 3 4 5 6 7
1 2 3 4 5 6 7
LoA m e ch an ic
LoA cognitive
LoA - Composites manufacturing
57
The assembly operations
4.2.1 Airframe Assembly
➢
➢
➢
➢
4.2.2 Process Flow
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Lo A me ch an ic
LoA cognitive
SoPI (1;7),(1;7)
58
4.2.3 Process Analysis
59
•
•
•
•
•
•
4.2.4 Final Assembly line (FAL)
•
•
•
1 2 3 4 5 6 7
1 2 3 4 5 6 7
LoA m e ch an ic
LoA cognitive
LoA - Airframe assembly
60
•
•
𝑆𝑜𝑃𝐼 → (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (1; 3)) ∧ (𝐿𝑜𝐴 𝑚𝑒𝑐 (1; 4)) 𝑆𝑜𝑃𝐼 = (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (1; 3)) ∗ (𝐿𝑜𝐴 𝑚𝑒𝑐 (1; 4)) = 12
1 2 3 4 5 6 7
1 2 3 4 5 6 7
LoA m e ch an ic
LoA cognitive
LoA - FAL
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Lo A me ch an ic
LoA cognitive
SoPI (1;3),(1;4)
61
Painting
•
•
•
4.3.1 Composite Paint shop – Medium parts
62 4.3.2 Final Painting
Raw Parts (CFRP or Metallic) arrive from Composite
shop
Clean Filler Clean Grinding
Primer Drying Grinding Clean Top Coating
To the assembly
line
63
➢
➢
➢
➢
➢
➢
➢
➢
Masking Filler/Grinding Primer Painting Drying
Painting Drying De-masking
64
𝑆𝑜𝑃𝐼 → (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (1; 3)) ∧ (𝐿𝑜𝐴 𝑚𝑒𝑐 (1; 3))
𝑆𝑜𝑃𝐼 = (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (1; 3)) ∗ (𝐿𝑜𝐴 𝑚𝑒𝑐 (1; 3)) = 9
1 2 3 4 5 6 7
1 2 3 4 5 6 7
LoA m e ch an ic
LoA cognitive
LoA- Painting process
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Lo A me ch an ic
LoA cognitive
SoPI (1;3),(1;3)
65
Intra-Logistics
➢
➢
➢
Sup p lier M an u fact u rin g P lan t Raw Materials Intermediates Finished Goods
W ar eh ouse
Shipping Storage Packaging
C u st omer
1 2 3 4 5 6 7
1 2 3 4 5 6 7
LoA m e ch an ic
LoA cognitive
LoA- Intra-Logistics
66
𝑆𝑜𝑃𝐼 → (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (1; 2)) ∧ (𝐿𝑜𝐴 𝑚𝑒𝑐 (1; 3)) 𝑆𝑜𝑃𝐼 = (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (1; 2)) ∗ (𝐿𝑜𝐴 𝑚𝑒𝑐 (1; 3)) = 6
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Lo A me ch an ic
LoA cognitive
SoPI (1;1), (1;2)
67
5 F UTURE F RAMEWORK - T OMORROW
Introduction
1. Current State
3. Future Actions
4.
Comparison Analysis
2. Future State
Framework Architecture
Axiomatic Design
Automated Composite Manufacturing
Square of Potential Improvements
Automated Assembly
Risk Assessment
Automated Painting Process
Automated Intra-
Logistics
68
→
Customer Domain
CN 1 : Rate 30 to 60 helicopters of each kind per year CN 2 : Reduction of customer - specific lead time CN 3 : Customization at the component level
CN 4 : Product Design must enable the production sequence CN 5 : Immediate testing after each process
CN 6 : Multiproduct assembly lines
CN 7 : Perceived quality anticipation
69
Composites Manufacturing
5.2.1 Composite Manufacturing- Axiomatic Design
✓
✓
✓
✓
70
D P 1 1 1 D P 1 1 2 D P 1 1 3 D P 1 1 4 D P 1 1 5 D P 1 1 6 D P 1 1 7 D P 1 1 8 D P 1 1 9 D P 1 1 1 0 D P 1 1 1 1 D P 1 1 1 2 D P 1 1 1 3 D P 1 2 1 D P 1 2 2 D P 1 2 3 D P 1 2 4 D P 1 2 5 D P 1 2 6 D P 1 2 7 D P 1 2 8 D P 1 2 9 D P 1 2 1 0 D P 1 2 1 1 D P 1 3 1 D P 1 3 2 D P 1 3 3
FR111 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR112 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR113 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR114 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR115 0 0 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR116 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR117 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR118 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR119 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1110 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1111 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1112 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1113 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR121 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 FR122 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 FR123 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 FR124 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 FR125 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 FR126 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 FR127 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 FR128 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 FR129 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 FR1210 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 FR1211 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 FR131 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 FR132 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 FR133 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
DP12
FR13 FR1
DP13 DP1
DP11
FR11
FR12
5.2.2 Square of Potential Improvements
71
✓
✓
✓
✓
✓
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Lo A me ch an ic
LoA cognitive
SoPI (5;7),(5;7)
72 5.2.3 Risk Analysis
Insufficient automation concept
Human operator/Robotic operator Handle and inspect
System not ready yet TRL:3-4
Many end effectors
Patch fibre placement
Vacuum assisted process Time consuming
Conventional automated fibre placement machine
Maturity of technology
Structure of parts
AFP machine operation
Resin Transfer Moulding
Cleaning of release agent tools
Material handling
Part diversity
Equipment Time
Inspection
Reach tolerances
73
Assembly Processes
✓
✓
✓
✓
✓
✓
✓
5.3.1 Axiomatic Design
74
•
•
•
75
DP111 DP112 DP113 DP114 DP115 DP116 DP117 DP118 DP119 DP1110 DP121 DP122 DP123 DP124 DP125 DP126 DP127 DP131 DP132 DP133 DP134 DP135 DP136 DP137 DP138 DP139 DP1310 DP1311 DP1312 DP1313 DP141 DP142 DP143 DP144 DP145 DP146 DP151 DP152 DP153 DP154 DP155 DP156 DP157 DP158 DP159 DP1510 DP161 DP162 DP163 DP164 DP165 DP166 DP167 DP168 DP169 DP1610 DP1611 DP171 DP172 DP173 DP174 FR111 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR112 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR113 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR114 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR115 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR116 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR117 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR118 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR119 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1110 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR121 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR122 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR123 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR124 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR125 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR126 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR127 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR131 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR132 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 1 1 0 1 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR133 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR134 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR135 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR136 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR137 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 1 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR138 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR139 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1310 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1311 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1312 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1313 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR141 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR142 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR143 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR144 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR145 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR146 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR151 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR152 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR153 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR154 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR155 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR156 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR157 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR158 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR159 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1510 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR161 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 FR162 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 FR163 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 FR164 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 FR165 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 FR166 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 1 0 0 0 0 0 0 0 0 0 FR167 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 0 0 1 0 0 0 0 0 0 0 0 FR168 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 FR169 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 FR1610 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 FR1611 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 FR71 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 FR172 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 FR273 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 FR374 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 FR11
FR1
DP1
DP11 DP16 DP17
FR16
FR17 FR12
FR13
FR14
FR15
DP12 DP13 DP14 DP15
76
✓
✓
✓
✓
✓
✓
77
✓
✓
✓
✓
∈
5.3.2 Risk Analysis
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Lo A me ch an ic
LoA cognitive
SoPI (4;7),(2;7)
78
Automated Assembly Risks
Accuracy Robot positioning
Environmental
Methodological
Material Software
Software
Ergonomics
Hole quality Jigs
HRC Co-bot
Cost Process technology
Accuracy Programming
Metrology Parts
Rivet Placement
People Variety
Clamping forces
Process Tooling
Location
Control system
Dosing accuracy Measurements
People A-plasma
Grit blasting
79
80
Painting Process
5.4.1 Axiomatic Design
✓
✓
81
D P1 11 D P1 12 D P1 13 D P1 14 D P1 15 D P1 16 D P1 17 D P1 18 D P1 19 D P1 11 0 D P1 11 1 D P1 11 2 D P1 11 3 D P1 11 4 D P1 11 5 D P1 21 D P1 22 D P1 23 D P1 24 D P1 25 D P1 26 D P1 27 D P1 28
FR111 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR112 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR113 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR114 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR115 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR116 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR117 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR118 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR119 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1110 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1111 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 FR1112 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 FR1113 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 FR1114 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 FR1115 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 FR121 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 FR122 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 FR123 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 FR124 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 FR125 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 FR126 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 FR127 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 FR128 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 FR12
FR1
DP11
FR11
DP12 DP1
5.4.2 Square of Potential Improvements
82
➢
➢
➢
➢
➢
➢
➢ →
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Lo A me ch an ic
LoA cognitive
SoPI (5;7),(5;6)
83
Inadequate Painting
Positioning
Programming Ink jet
Paint jet
Offline system Separate parts
Singularities (robot Weaknesses)
Filler
Plasma activation Grinding
No part assortment in the workshop Software
Liquid
Intra-Logistics
✓
✓
84 5.5.1 Axiomatic Design
D P 1 1 1 D P 1 1 2 D P 1 1 3 D P 1 1 4 D P 1 1 5 D P 1 1 6 D P 1 1 7 D P 1 1 8 D P 1 1 9 D P 1 1 1 0 D P 1 2 1 D P 1 2 2 D P 1 2 3 D P 1 2 4 D P 1 2 5 D P 1 2 6 D P 1 2 7 D P 1 2 8 D P 1 2 9 D P 1 2 1 0 D P 1 2 1 1 D P 1 2 1 2
FR111 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR112 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR113 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR114 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR115 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR116 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR117 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR118 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 FR119 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 FR1110 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 FR121 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 1 1 FR122 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1 1 FR123 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 FR124 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 FR125 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 FR126 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 FR127 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 FR128 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 FR129 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 FR1210 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 FR1211 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 FR1212 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1
DP11
FR11
FR12 FR1
DP12
DP1
85 5.5.2 Square of Potential Improvements
✓
✓
✓
✓
✓
✓
𝑆𝑜𝑃𝐼 → (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (2; 7)) ∧ (𝐿𝑜𝐴 𝑚𝑒𝑐 (6; 7)) 𝑆𝑜𝑃𝐼 = (𝐿𝑜𝐴 𝑖𝑛𝑓𝑜 (2; 7)) ∗ (𝐿𝑜𝐴 𝑚𝑒𝑐 (6; 7)) = 12
1 2 3 4 5 6 7
1 2 3 4 5 6 7
Lo A me ch an ic
LoA cognitive
SoPI (1;1), (1;2)
86 5.5.3 Risk Analysis
Insufficient Intra-Logistics System
Collaborative Robot
Task variety Jigs
Materials Reconfigurability
Unsuccessful loading
Harm to People Control system
Battery Factory layout
Moving
Overheat
87
6 F UTURE A CTIONS – W ORK P LAN
1. Current State
3. Future Actions
4.
Comparison Analysis
2. Future
State
88
Feasible area of automation (Perfect SoPI)
Future SoPI (Maximum improvements)
Current SoPI (Minimum improvements)
1 LoA info 7
7
LoA mec
1
✓
✓
Cost – Benefit Analysis
•
•
•
89
•
•
•
•
•
90
Analytic Hierarchy process
91
92
𝝀 𝒎𝒂𝒙 = 𝟑, 𝟎𝟑) Monetary
criteria
Integrated automation
cost O&M cost
Strategic considerations
Risk
Benefits
Growth
Performance measures
Opportunities
Technology Maturity level
Concept Acceptance
Level of Automation
Scenario "Current State"
Scenario "Future
State"
93
(𝝀 𝒎𝒂𝒙 = 𝟑, 𝟎𝟑
94 (𝝀 𝒎𝒂𝒙 = 𝟑, 𝟐
(𝜆 𝑚𝑎𝑥 = 𝟐, 𝟔𝟔
95
Choosing the alternatives – New - Current State
1 st Performance Measures
•1 Opportunities
•2 Concept Acceptance
•3 Technology Maturity
2 nd Strategic Considerations
•1 Risks
•2 Benefits
•3 Growth
3 rd Monetary Criteria
•Integrated Automation Costs
•O&M Costs
96
Scenario 1
"Current State"
Scenario 2
"Future State"
97
Feasible Level of Automation (Perfect SoPI)
Future SoPI (Maximum improvements)
Current SoPI (Minimum improvements)
1 LoA info 7
7
LoA mec
1
Future Implementation
98
✓
✓
✓
99
Part III
Discussions and Conclusions
100
7 D ISCUSSIONS AND C ONCLUSIONS
Comparison Analysis
•
•
•
•
1. Current State
3. Future Actions
4.
Comparison Analysis
2. Future
State
101
Discussion
102
Conclusions
103
104
R EFERENCES
105
106
107
108
109
110
I
APPENDIX
II
A PPENDIX 1
III
IV
→
V
VI
VII
VIII
IX
X
Process Paramete
r number Risk parameters Mitigation Action Comments
1 Accuracy
The accuracy of industrial robots can be improved using localized sensors and global referencing (Maropoulos et al. 2014) A combination of process improvements, tighter tolerances in the single parts and adjusting single part geometries could possibly solve the edge distance issue (Jaacks, 2016)
The proposed technology (cobots) need efficient off-line programming.
The supplier has to take into serious consideration the metrology system
2 Quality assurance
Every measurement must be accompanied by an evaluation of its uncertainty (Maropoulos et al. 2014)
This method increases the potential of the automated measurement.
3 Robot positioning
External measuring system for end effector and robot using an iterative feedback. A flexible digitizing system can reduce the number of
repositioning stages and alignments and shorten the overall measurement time (Jamshidi et al. 2009)
The approach is known as "adaptive control" where the iteration in the positioning continues until a satisfactory level of deviation from the nominal position is achieved (Jamshidi et al. 2009) However the risk is mitigated to medium as in aerospace those deviations are undesirable.
4 Methodological
Flexible digitizing system can reduce the number of repositioning stages and alignments and shorten the errors and uncertanty in measurement results (Jamshidi et al. 2009)
The tolerances and sizes of the components should also be designed in such a way that the measurability is also considered alongside the product functionality. (Jamshidi et al.
2009) This excels from the manual measurement approach so the highest level of automation is recommended.
5 Environmental
1 Shimming material
1.1 Solid application
The algorithm for shim generation is capable of distinguishing between the type of shim required and produces solid shimsonly when required
The proposed automated technique from Ehmke et al. (2017) is an adequate solution (hence "low" risk)
1.2 Liquid (adhesive application)
Increase the volume of the applied adhesive by an incremental factor while decreasing the robot velocity at the start and the end of the
component to compensate for narrow regions (Ehmke et al. 2017)
Using this approach, the liquid shimming lead time is increased to 3%.
2 Measurements
Measurement data of CFRP before the assembly, manual NDT testing (Ehmke et al. 2017)
As the measurement process cannot be totally integrated automatically and the error derives from the gap volume measurement is not decreased (Ehmke et al. 2017), LoA = 7 is not possible due to risks.
A u to m ate d M e as u re m e n t A u to m ate d S h im m in g
XI
1 Robot
Cobot utilization is a safe choice as soon as there is a human presence (based on Brötje automation presentation)
Case study inquiry has been sent to a supplier. The results will point out the potential risks. However there are still doubts regarding the part-to- part drilling due to cobot's strength (up to 10kg)
2 HRC
Personalized safety framework (Wang et al. 2018) Safety measures in a cooperative space eliminate the risk level of the sharing worktask.
3 Jigs
Eliminate the costs by using the same jigs (based on Brötje interview);
measurement tools (as stated above);
moving jig
As stated in personal interview by Brötje Automation, the already existing jigs can be used. The position must not block human and cobot movement (intelligent jig -->
increase the LoA)
4 Hole quality
Use of accurate measurement tooling and programs; robot positioning and referencing; a machine can assure better normality; design larger parts and tighter tolerances (Jaacks, 2016)
In the manual process, insufficient hole positions are detected by the operator. On the other hand, robots cannot see the couplings and stringers on the inside. Instead design and process modifications must be conducted to increase robot's potential (Jaacks, 2016)
5 Ergonomics
Eliminate the dangerous movements for the drilling operation. Adapting flexible tooling, people don’t need to climb or to "dig" in order to drill.
People can be used only for inspection instead of coping with moving big structures or robotic platforms and iterative drilling
The cobot's also protect the human by the safety framework and operating for longer time so no pain or accidents from the tooling or the sharp edges can harm the human operator anymore.
6 Cost
Cobot equipment is commonly less expensive from the conventional robots. The cost factor is only increased on the software where the risk is unmitigated
7 Process technology
Choose the most efficient technology based on cobot's abilities.
1 Metrology
Design products to enable jigless assembly. Also, using geometric product specification (GPS), define the maximum permissible degree of variation of a component by allocating the shape, dimensions and
characteristics of the given component with referencing to given datums. (Francis et al. 2016)
The proposed methodology considers the metrology errors are acceptable at the aerospace industry
2 Programming
A Matlab based optimization code was developed by UK's national physical laboratory (NPL) for laser tracker position provides early stage design limits for assigning tolerance limits and desired confidence levels (Francis et al. 2016)
The code must be implemented within the Design for Verification framework by Francis et al. (2016)
3 Parts variety
The jig can obtain the part's geometry
(Broetje automation interview, 2019) This statement was part of a private interview. The company produces tailor made jigs for the aerospace industry, hence the jigs are powerful and structured to cope with accuracy and reconfigurability to the various aerospace parts demands.
4 Accuracy
Using the metrology assisted assembly framework provide real time metrological verification for jig setting and assembly alignment. (Francis et al. 2016)
The primary concern is to maintain the ability of accuracy after certain reconfigurations. The framework is used for risk mitigation at measurement activity and as design parameter.
A u to m ate d D ri lli n g A u to m ate d P o si ti o n in g
XII
XIII
XIV
XV
Process No. Risk parameters Mitigation Action Comments
1
Positioning
The risks can be avoided through refined cell design or configuration or careful motion programming through the feature "motion through singularity" ensures that the robot moves in through singularity in a predictable and safe manner. (Becroft, 2012)
"Singularities" are the mathematical errors which cause unitended motion or motion stop (calculation for that position is undefined) and those risks most of the times are unavoidable.
Part location systems (PLS) are mathemating programs that use sensors to locate multiple targets on the part to determie its location and offset the programs for the part location tolerances. (Becroft, 2012) Hence it is possible to develop a system that will place the separate parts in the accurate position for design painting of the final structure.
2
Programming
Use vision technology to determine key aspects of the part to be painted and then to input those aspects into a special software program that will generate the motion program for each part.The programs used for the manipulator are best taught using an offline programming system(OPS).
(Becroft, 2012)
This technology can eliminate the unique motion programming for each part and help make an automated painting system feasible and cost effective. (Becroft, 2012) The OPS derive CAD date, physical relationships of part an
dmanipulator, motion algorithms to control the motion, simulation of the applicator.
3
Ink jet
Print directly to the part on 3D in a single run. No human in the painting booth (no health damages). The technology decrease the wastes, is energy and cost efficient.
The technology is under development.
4
Paint jet
The technology has several requirements an is under development.
Currently no thorough suggestion is available.
1 Filler As seen in "Automated Assembly -
Automated adhesive application"
2
Plasma activation
As seen in "Automated Assembly" the risks regarding plasma activation plus the cycle time will be decreased.
3
Grinding
The risks derive from the manual process are decreased significantly (hit by workpiece, hot surfaces etc.)
4
No part assortment
Using an OPS (Becroft, 2012) it is possible to develop individual painting schemes that will not affect the painting process even the parts are completely different.
Pre-mitigation, it causes obstacles to the smooth flow for a robotic system.
A u to ma te d F in a l P a in ti n g A u to ma te d P ri me r A p p li ca ti o n
XVI
XVII
XVIII
A PPENDIX 2
Department Station
Number of workstations
Lead Time Commercial
HC Inputs Process Flow Process Details
Number of Rivets
Types of Rivets
Material used in the structure (numbers)
Weight (kg)
St.1 - Top airframe
assembly 2 12 days
Joining of cabin airframe with top frame. Remains to
storage until St.4 410 3 2 22 or 28
St.2 - Bottom
shell 4
17 days
Joining of bottom shell. The bottom shell is being painted and returns to the workshop in the temporary storage area. Remains to storage until St.4
2389 4 4 55
St.3 - Center
fuselage 2 17 days
Joining cabin airframe (St.1) and main fuselage. Remains to storage until St.4
1666 5 5 72
ST. 4 - Final fuselage
assembly 1 16 days
Final station. The assembled components from St.1, St.2, St.3 are assembled in this station. After this station the product goes for primaring.
2178 4 4 207
Industrial Manufacturing Flow Chart In-house processes
Airframe Assembly
Cabin airframe
Joining
Bottom shell Composite parts
Top frame
Painting shop Back to Department
Fuselage (external)
Main fuselage assembly
Integrated
fuselage frame
assembly
Landing Gear
XIX
Department Workstation Lead Time (days) Inputs Process Flow Process Instructions
St.1 4
St.2 4
St.3 4
St. 4 4
Painting
Shop St. 5 8
St.6 3
St. 7 13
St. 8 17
Flight Line
St. 9 24
Helicopter Industrial Manufacturing Flow Chart In-house processes
Final Assembly
Line
Final Assembly
Line
Instruments Structure Part I
Structure Part II Windshields
Main gearbox
Engines
Structure Part III
Avionic SystemsCommunication Systems
