Reconfigurable Assembly Modules for Multi-Product Production Lines
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Solution Overview
Problem
Manufacturers face challenges in rapidly and cost-effectively reconfiguring production lines to adapt to changing production models and consumer demands, leading to increased costs and decreased profitability due to the need for frequent line constructions and the inability to efficiently produce diverse, small-quantity products.
Innovation Solution
A flexible assembly system that uses standardized reconfigurable assembly modules (RAMs) and a network-based method to design, verify, and reconfigure production lines, allowing for rapid and accurate configuration by transmitting design information to onsite installers and verifying component arrangements, enabling the production of multiple product types on a single line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a production line is constructed for a new model, then the ability to produce new products is improved, but the construction cost and time increase
Solution Approach 1:
The production line is divided into modular assembly modules (AMs) that can be independently configured and reconfigured. Each AM performs a specific production process, and modules can be rearranged or replaced to accommodate new product models without constructing an entirely new production line, thereby reducing construction time and cost while maintaining adaptability to new products
Solution Approach 2:
The production line configuration is made dynamic and reconfigurable through standardized interfaces and modular design. Assembly modules can be dynamically rearranged, added, or removed based on production requirements, enabling rapid adaptation to new product models without significant construction time or cost increases
2Adaptability or versatility
If a production line is constructed for a new model, then the ability to produce new products is improved, but the construction cost increases
Solution Approach 1:
Assembly modules are designed with universal interfaces and standardized configurations that allow them to perform multiple functions across different product models. A single modular assembly module can be reconfigured to produce various products, eliminating the need to construct entirely new production lines for each model, thereby reducing construction costs while maintaining the ability to produce new products
Solution Approach 2:
When transitioning to new product models, existing assembly modules that are no longer needed for specific processes can be discarded from the old configuration and recovered/reused in new configurations for the updated production line, reducing the need for new construction and lowering overall construction costs
3Stability of the object's composition
If traditional production lines are used, then production stability is maintained, but the ability to respond to market changes decreases
Solution Approach 1:
The production line is segmented into independent modular assembly modules with standardized interfaces. This segmentation allows individual modules to be reconfigured or replaced without disrupting the entire production system, maintaining overall production stability while enabling rapid adaptation to market changes through localized modifications
Solution Approach 2:
The system enables parameter changes in production configuration through modular reconfiguration. By changing the arrangement, type, or configuration parameters of assembly modules rather than the entire production line, the system maintains stable production operations while adapting to market demands
Data Source
AI summary
A flexible assembly system for multi-product production and a method of reconfiguring a production line for multi-product production. A method of designing a production line includes configuring reconfigurable assembly modules (RAMs) for each production process of the production line using components included in a production line configuring tool, verifying a production amount of each of the RAMs using a production line simulator, designing the production line using RAMs with a production amount greater than or equal to a threshold value, and transmitting design information of the production line to an onsite production line installer terminal.