Design of a Solution for Blind Assembly of Bolts - Assembly of Low-visibility Bumper Bolts with a Focus on Ergonomics and Safety

Abstract

This project focuses on the assembly of low-visibility bumper bolts under the truck model known as the Volvo FML- a process currently not possible on the assembly line due to challenging posture and safety hazards. The project seeks to solve these challenges and ultimately allow Volvo Trucks in Tuve to shift this assembly from an after-line area where it is done presently, to the main line. A linear product development methodology has been used with iterative test-design-build cycles inspired by lean principles. This was chosen over a more flexible, agile methodology to make it easier to coordinate activities with Volvo. A thorough pre-study was conducted to lay the theoretical groundwork for the project, which included both researching existing solutions to similar problems, and a detailed study of the current state. The current state analysis was then used to add detail to the problem statement. Key stakeholders were identified and continually contacted throughout the project to ensure the fulfilment of their interests in the project’s outcome. Concept generation was conducted, which yielded 14 unique concepts in different phases of the project, while keeping the solution space as open as possible. Importance was placed on thoroughly documenting concept generation for Volvo’s future reference. Selection and elimination matrices were used to refine or identify the best performing concepts in the initial stages, which yielded 3 concepts to prototype. The 3 prototypes were developed, and further elimination to obtain the winning concept was conducted at the last possible stage, only when feasibility or suitability was deemed impossible. User testing and verification was conducted, which revealed the winning concept and resulted in 4 design changes to it. Well-researched ergonomics and safety testing methodologies were employed to verify suitability of the suggested solution. The final solution was tested on the moving assembly line, on the Volvo FML. One crucial trade-off was made, in the interest of ease of maintenance. Other suitable solutions have been suggested, with clear reasoning behind why they were not developed. The final solution solves the problem that has been proposed by Volvo.