Analyzing manual assembly complexity using a combination of RD&T and IPS IMMA: Validation, proposal of improvements and suggested imple mentation of the software in the work process at CEVT

Abstract

In the industry, especially the automotive industry, manual assembly is still a signifi cant part of the manufacturing process. In previous research, it has been established that higher manual assembly complexity increases the risk of operator mistakes and thereby may lead to poorer geometrical quality. Therefore, a new software combin ing the geometry assurance program RD&T and the ergonomics evaluation program IPS IMMA was developed. The program was created to gain information regard ing manual assembly complexity earlier in the product development process before changes become more costly. In this master thesis, the research questions considered whether a validation could be performed on the combined program for a case study, finding potential improve ments for the program, and how it could be implemented in the work process at CEVT. The project was divided into three phases, preparation, implementation, and analysis. In the preparation phase, the project was defined and a literature study was performed. In the implementation phase, the validation of the program and interviews were conducted and in the analysis phase, the result from the imple mentation phase was analyzed. The validation for the program was a comparison between a manual assessment and the result of the simulation program. The result of the validation was highly impacted by the tuning of the criteria and the limitation of only performing one assembly movement. The conclusion was that the program is not yet ready to be validated. From the validation and the interviews, several improvements were sug gested for the program. The interviews provided potential functions based on needs and improvements regarding use in work. The validation contributed to more spe cific improvements, based on observations from the performed validation. For the implementation in the work processes, it was proposed the analysis of the combined program should be performed by either the geometry department or a support func tion in the design departments. The general responsibility for the analysis would be shared with the manufacturing feasibility department.