Advertisement

A novel concept of bent wires sorting operation between workstations in the production of automotive parts

  • A. J. A. Magalhães
  • F. J. G. SilvaEmail author
  • R. D. S. G. Campilho
Technical Paper
  • 31 Downloads

Abstract

The most important goals pursued by the automotive industry for a long time are the quality and the delivery time. In order to ensure that such premises are fulfilled, it is necessary that these companies have machines with fast production cycles and versatile layouts, able to adapt to the production of a large number of different parts. At the same time, for some production lines to spend the shortest possible time, it is necessary that there are devices able to quickly perform the transposition from one stage of production to the next one, freeing operators to more attractive and personalized tasks. Thus, simultaneously it is possible to reach higher production cadences, with the corresponding financial gains, as well as an increase in workers motivation, which will be more productive. In this work, a novel concept of interconnection system between different manufacturing processes is presented in order to overcome the usual waste of time. Moreover, it is intended to show that, by replacing some robotized operation by cheaper automatic systems, it is possible to reduce the cycle time and improve the quality of the parts delivery from one operation to the next one. A case study is also presented corroborating this idea and showing how this principle can be applied in the field. The case study intends to show a novel device able to link the wire bending process and the further stage, the polymer over-injection process, in cushions and suspension mats for automotive seats.

Keywords

Automation Bending wires Automatic systems Conveyor system Sorting Low-cost solutions 

Notes

Acknowledgements

The authors wish to thank Mr. Mário Cardoso from PR METAL, Lda., for his collaboration and commitment in providing the necessary data when this project started, giving the necessary inputs every time they were needed during the case study development.

References

  1. 1.
    Antoniolli I, Guariente P, Pereira T, Pinto Ferreira L, Silva FJG (2017) Standardization and optimization of an automotive components production line. Procedia Manuf 13:1120–1127.  https://doi.org/10.1016/j.promfg.2017.09.173 CrossRefGoogle Scholar
  2. 2.
    Guariente P, Antoniolli I, Pinto Ferreira L, Pereira T, Silva FJG (2017) Implementing autonomous maintenance in an automotive components manufacturer. Procedia Manuf 13:1128–1134.  https://doi.org/10.1016/j.promfg.2017.09.174 CrossRefGoogle Scholar
  3. 3.
    Hu SJ (2013) Evolving paradigms of manufacturing: from mass production to mass customization and personalization. Procedia CIRP 7:3–8.  https://doi.org/10.1016/j.procir.2013.05.002 CrossRefGoogle Scholar
  4. 4.
    Michalos G, Makris S, Papakostas N, Mourtzis D, Chryssolouris G (2010) Automotive assembly technologies review: challenges and outlook for a flexible and adaptive approach. CIRP J Manuf Sci Technol 2:81–91.  https://doi.org/10.1016/j.procir.2016.11.109 CrossRefGoogle Scholar
  5. 5.
    Staats BR, James D, Upton DM (2011) Lean principles, learning and knowledge work: evidence from a software services provider. J Oper Manag 29(5):376–390.  https://doi.org/10.1016/j.jom.2010.11.005 CrossRefGoogle Scholar
  6. 6.
    Costa RJS, Silva FJG, Campilho RDSG (2017) A novel concept of agile assembly machine for sets applied in the automotive industry. Int J Adv Manuf Technol 91(9–12):4043–4054.  https://doi.org/10.1007/s00170-017-0109-4 CrossRefGoogle Scholar
  7. 7.
    Holweg M (2008) The evolution of competition in the automotive industry. In: Glenn P, Graves AP (eds) Build to order: the road to the 5-day car. Springer, Berlin, pp 13–34. ISBN 978-1-84800-225-8CrossRefGoogle Scholar
  8. 8.
    Larsson A (2002) The development and regional significance of the automotive industry: supplier parks in western Europe. Int J Urb Reg Res 26(4):767–784.  https://doi.org/10.1111/1468-2427.00417 MathSciNetCrossRefGoogle Scholar
  9. 9.
    Shah R, Ward PT (2007) Defining and developing measures of lean production. J Oper Manag 25(4):785–805.  https://doi.org/10.1016/j.jom.2007.01.019 CrossRefGoogle Scholar
  10. 10.
    Yang MG, Hong P, Modi SB (2011) Impact of lean manufacturing and environmental management on business performance: an empirical study of manufacturing firms. Int J Prod Econ 129(2):251–261.  https://doi.org/10.1016/j.ifacol.2016.07.552 CrossRefGoogle Scholar
  11. 11.
    Eroglu C, Hofer C (2011) Lean, leaner, too lean? The inventory-performance link revisited. J Oper Manag 29(4):356–369.  https://doi.org/10.1016/j.jom.2010.05.002 CrossRefGoogle Scholar
  12. 12.
    Scherrer-Rathje M, Boyle TA, Deflorin P (2009) Lean, take two! Reflections from the second attempt at lean implementation. Bus Horiz 52(1):79–88.  https://doi.org/10.1016/j.bushor.2008.08.004 CrossRefGoogle Scholar
  13. 13.
    Losonci D, Demeter K, Jenei I (2011) Factors influencing employee perceptions in lean transformations. Int J Prod Econ 131(1):30–43CrossRefGoogle Scholar
  14. 14.
    Araújo LMB, Silva FJG, Campilho RDSG, Matos JA (2017) A novel dynamic holding system for thin metal plate shearing machines. Robot Comput Integr Manuf 44:242–252.  https://doi.org/10.1016/j.rcim.2016.06.006 CrossRefGoogle Scholar
  15. 15.
    Treville S, Shapiro RD, Hameri AP (2004) From supply chain to demand chain: the role of lead time reduction in improving demand chain performance. J Oper Manag.  https://doi.org/10.1016/j.jom.2003.10.001 CrossRefGoogle Scholar
  16. 16.
    Salvador F, Forza C, Rungtusanatham M (2002) Modularity, product variety, production volume, and component sourcing: theorizing beyond generic prescriptions. J Oper Manag 20(5):549–575.  https://doi.org/10.1016/S0272-6963(02)00027-X CrossRefGoogle Scholar
  17. 17.
    Sullivan WG, McDonald TN, Van Aken EM (2002) Equipment replacement decisions and lean manufacturing. Robot Comput Integr Manuf 18(3–4):255–265.  https://doi.org/10.1016/S0736-5845(02)00016-9 CrossRefGoogle Scholar
  18. 18.
    Mishina K (1995) Toyota motor manufacturing, U.S.A., Inc. vol 2(3)Google Scholar
  19. 19.
    Li J, Nakano M, Cai W, Furmans K, Patchong A (2010) Guest editorial: automation in automotive manufacturing. IEEE Trans Autom Sci Eng 7(4):721–723.  https://doi.org/10.1109/TASE.2010.2051510 CrossRefGoogle Scholar
  20. 20.
    Groover MP (2000) Automation, production systems, and computer-integrated manufacturing, 2nd edn. Prentice Hall, New Jersey. ISBN 0-13-239321-2Google Scholar
  21. 21.
    Rizzoni G (2005) Introduction to electrical engineering. In: Principles and applications of electrical engineering, McGraw-Hill. Cap. 1, pp 1–8. ISBN: 0-07-322033-7Google Scholar
  22. 22.
    Nunes PMS, Silva FJG (2013). Increasing flexibility and productivity in small assembly operations: a case study In: Azevedo A (ed) Advances in sustainable and competitive manufacturing systems 23rd international conference on flexible automation and intelligent manufacturing, Springer, Switzerland, pp 329–340.  https://doi.org/10.1007/978-3-319-00557-7_27
  23. 23.
    Ford M (2009) The lights in the tunnel: automation, accelerating technology and the economy of the future. Acculant Publishing, USA. ISBN 1-4486-5981-7Google Scholar
  24. 24.
    Abreu P (2002). Robótica Industrial M.Sc. thesis, Faculty of Engineering, University of Porto, Porto. (in Portuguese)Google Scholar
  25. 25.
    Wise E (2005) Robotics demystified. McGraw-Hill, New York. ISBN 0-07-143678-2Google Scholar
  26. 26.
    Araújo WFS, Silva FJG, Campilho RDSG, Matos JA (2017) Manufacturing cushions and suspension mats for vehicle seats: a novel cell concept. Int J Adv Manuf Technol 90:1539–1545.  https://doi.org/10.1007/s00170-016-9475-6 CrossRefGoogle Scholar
  27. 27.
    Costa MJR, Gouveia RM, Silva FJG, Campilho RDSG (2017) How to solve quality problems by advanced fully-automated manufacturing systems. Int J Adv Manuf Technol.  https://doi.org/10.1007/s00170-017-0158-8 CrossRefGoogle Scholar
  28. 28.
    Moreira BMDN, Gouveia RM, Silva FJG, Campilho RDGS (2017) A novel concept of production and assembly processes integration. Procedia Manuf 11:1385–1395.  https://doi.org/10.1016/j.promfg.2017.07.268 CrossRefGoogle Scholar
  29. 29.
    Lavvafi H, Lewandowski JR, Lewandowski JJ (2014) Flex bending fatigue testing of wires, foils, and ribbons. Mater Sci Eng A 601:123–130.  https://doi.org/10.1016/j.msea.2014.02.015 CrossRefGoogle Scholar
  30. 30.
    Gupta Shikha, Pelton Alan R, Weaver Jason D, Gong Xiao-Yan, Nagaraja Srinidhi (2015) High compressive pre-strains reduce the bending fatigue life of nitinol wire. J Mech Behav Biomed Mater 44:96–108.  https://doi.org/10.1016/j.jmbbm.2014.12.007 CrossRefGoogle Scholar
  31. 31.
    Zhang D, Feng C, Chen K, Wang D, Ni X (2017) Effect of broken wire on bending fatigue characteristics of wire ropes. Int J Fatigue 103:456–465.  https://doi.org/10.1016/j.ijfatigue.2017.06.024 CrossRefGoogle Scholar
  32. 32.
    Pal U, Mukhopadhyay G, Sharma A, Bhattacharya S (2018) Failure analysis of wire rope of ladle crane in steel making shop. Int J Fatigue 116:149–155.  https://doi.org/10.1016/j.ijfatigue.2018.06.019 CrossRefGoogle Scholar
  33. 33.
    Cao X, Wu W (2018) The establishment of a mechanics model of multi-strand wire rope subjected to bending load with finite element simulation and experimental verification. Int J Mech Sci 142–143:289–303.  https://doi.org/10.1016/j.ijmecsci.2018.04.051 CrossRefGoogle Scholar
  34. 34.
    Bonneric M, Aubin V, Durville D (2018) Finite element simulation of a steel cable—rubber composite under bending loading: influence of rubber penetration on the stress distribution in wires. Int J Solids Struct.  https://doi.org/10.1016/j.ijsolstr.2018.10.023 CrossRefGoogle Scholar
  35. 35.
    Rosa C, Silva FJG, Ferreira LP (2017) Improving the quality and productivity of steel wire-rope assembly lines for the automotive industry. Procedia Manuf 11:1035–1042.  https://doi.org/10.1016/j.promfg.2017.07.214 CrossRefGoogle Scholar
  36. 36.
    Rosa C, Silva FJG, Ferreira LP, Campilho R (2017) SMED methodology: the reduction of setup times for Steel Wire-Rope assembly lines in the automotive industry. Procedia Manuf 13:1034–1042.  https://doi.org/10.1016/j.promfg.2017.09.110 CrossRefGoogle Scholar
  37. 37.
    Rosa C, Silva FJG, Ferreira LP, Pereira T, Gouveia R (2018) Establishing standard methodologies to improve the production rate of assembly lines used for low added-value products. Procedia Manuf 17:555–562.  https://doi.org/10.1016/j.promfg.2018.10.096 CrossRefGoogle Scholar
  38. 38.
    NR 10: 2004 standard—Segurança em Instalações e Serviços em Electricidade. http://www.ccb.usp.br/arquivos/arqpessoal/1360237189_nr10atualizada.pdf. Accessed 26 Feb 2018
  39. 39.
    NR 12: 2016 standard—machinery and work equipment safety. http://www.braziliannr.com/brazilian-regulatory-standards/nr12-machinery-and-work-equipment-safety/. Accessed 26 Feb 2018

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2018

Authors and Affiliations

  • A. J. A. Magalhães
    • 1
  • F. J. G. Silva
    • 1
    Email author
  • R. D. S. G. Campilho
    • 1
  1. 1.ISEP (School of Engineering Polytechnic of Porto)PortoPortugal

Personalised recommendations