Applications and benefits of digital human models to improve the design of workcells in car’s manufacturing plants according to international standards

During last years, the car’s manufacturing process has deeply changed because of several factors affected the automotive global scenario. As a consequence, design methodologies of the plant’s workcells have changed. In particular, ergonomics for manufacturing system has become a key factor to improve product’s quality, safety and work organization. In this paper, the authors show the approach used in Fiat Group Automobiles (FGA) based on simulation tools to analyse ergonomic aspects of work-cells already in design phase. Simulation tools allow a deep postural analysis that is one of the main criticism in the design phase. The principles of Digital Human Modeling have been used to develop an easy internal virtual manikin, the Human Model. The tool, based on ISO standards and on a worldwide anthropometric database, allows designers to simulate the most probable postures engaged by operator during work tasks as well as to validate improvements and corrective actions

Designing a dexterous reconfigurable packaging system for flexible automation

This paper presents a design for a reconfigurable packaging system that can handle cartons of different shape and sizes and is amenable to ever changing demands of packaging industries for perfumery and cosmetic products. The system takes structure of a multi-fingered robot hand, which can provide fine motions, and dexterous manipulation capability that may be required in a typical packaging-assembly line. The paper outlines advanced modeling and simulation undertaken to design the packaging system and discusses the experimental work carried out. The new packaging system is based on the principle of reconfigurability, that shows adaptability to simple as well as complex carton geometry. The rationale of developing such a system is presented with description of its human equivalent. The hardware and software implementations are also discussed together with directions for future research

Cost minimization for unstable concurrent products in multi-stage production line using queueing analysis

This research and resulting contribution are results of Assumption University of Thailand. The university partially supports financially the publication.Purpose: The paper copes with the queueing theory for evaluating a muti-stage production line process with concurrent goods. The intention of this article is to evaluate the efficiency of products assembly in the production line. Design/Methodology/Approach: To elevate the efficiency of the assembly line it is required to control the performance of individual stations. The arrival process of concurrent products is piled up before flowing to each station. All experiments are based on queueing network analysis. Findings: The performance analysis for unstable concurrent sub-items in the production line is discussed. The proposed analysis is based on the improvement of the total sub-production time by lessening the queue time in each station. Practical implications: The collected data are number of workers, incoming and outgoing sub-products, throughput rate, and individual station processing time. The front loading place unpacks product items into concurrent sub-items by an operator and automatically sorts them by RFID tag or bar code identifiers. Experiments of the work based on simulation are compared and validated with results from real approximation. Originality/Value: It is an alternative improvement to increase the efficiency of the operation in each station with minimum costs.peer-reviewe

The development of a finite elements based springback compensation tool for sheet metal products

Springback is a major problem in the deep drawing process. When the tools are released after the forming stage, the product springs back due to the action of internal stresses. In many cases the shape deviation is too large and springback compensation is needed: the tools of the deep drawing process are changed so, that the product becomes geometrically accurate after springback. In this paper, two different ways of geometric optimization are presented, the smooth displacement adjustment (SDA) method and the surface controlled overbending (SCO) method. Both methods use results from a finite elements deep drawing simulation for the optimization of the tool shape. The methods are demonstrated on an industrial product. The results are satisfactory, but it is shown that both methods still need to be improved and that the FE simulation needs to become more reliable to allow industrial application