Determination of extended availability and productivity for assembly systems using existing data base

doi:10.1016/j.cirp.2012.03.023

CIRP Annals

Volume 61, Issue 1, 2012, Pages 17-20

https://doi.org/10.1016/j.cirp.2012.03.023 Get rights and content

Abstract

Reliable information about the operational availability of assembly or production systems is of great importance for the users of complex production facilities, especially when such facilities operate at their capacity limit. Nowadays, in most cases, the availability of assembly systems is monitored and evaluated using collected status data. This paper presents a new approach for permanent productivity determination of assembly systems based on the usage of in-process acquired product data. This approach is especially applicable for manufacturing systems that produce goods for which complete product traceability is required.

Section snippets

Situation and initial status

Machines and production systems in assembly are becoming increasingly complex in terms of their structure and function [1], [2]. Nevertheless, users even of those complex systems expect their manufacturers to guarantee high quality levels and availability for such production facilities [3]. The authoritative definition of the term availability with respect to production facilities helps the manufacturer and the user of the facility to develop a uniform perception of the reliability of these

Approach using extended product data

The product data, basically stored for quality assurance and the task of product traceability, represents the central data basis for the shown new approach to determine the productivity of modular assembly systems using in-process acquired product data. Fig. 1 depicts a new process model applied to determine the productivity of a complex interlinked production system using such extended product data.

Initially it is assumed, that for each station PS⁽ⁱ⁾ (i = 1, …, n; n: number of stations to be

Model evaluation using material flow simulation

For the evaluation of the introduced product data based calculation approach, simulation-based generated data was used. Thus data is generated using a material flow simulation method which emulates a realistic production system (see Fig. 7) including realistic disturbance reaction, assembly of different product types, shift systems and reworking of bad parts.

Using a simulation system to generate the data has important advantages:

•
Performing experiments with different simulation parameters (e.g.

Conclusion

The use of product data as a basis for determining as well as for monitoring the productivity of production systems is reasonable for characterizing assembly systems, especially because of the requirement to collect product data and make it available for tasks of product traceability. The proposed approach allows the determination of the OEE for the overall system as well as for individual stations without additional expenditure for collecting the necessary system data [8]. One important

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