State-of-the-art assembly planning
More flexibility and efficiency with our assembly planning
Assembly planning where every move is perfect
The goal of our consulting and assembly planning is to assign a series of tasks that must be performed on the workpiece to a sequence of workstations. Each task requires a specific task duration for its completion. Assignment of tasks to stations is usually accomplished by assembly precedence graphs, which indicate which tasks must be completed before a particular task can be started. In addition, scheduling is constrained by a cycle time, which limits the sum of task durations that can be completed at each workstation before the workpiece is moved off the conveyor to the next station. Key planning issues in assembly line operations include supply chain integration, inventory control, and production scheduling.
Current trends around the assembly
Our assembly planning focuses on making assembly processes more flexible, adaptable and nimble to cope with increasing product diversity and market volatility. This requirement affects equipment, personnel, production organization, and decision-making processes. For example, product customization moves product identification, i.e., the assignment of a specific workpiece to a specific customer order, earlier in the production process. One reason it is difficult for manufacturers to fill both skilled and unskilled positions is the lack of vocational school opportunities for young men and women. To solve this problem, many manufacturers are developing robust apprenticeship programs to teach candidates everything from toolmaking and welding to robot programming and sheet metal rolling.
Mounting system – getting the optimum out of it
In many companies, assembly is the core business. It must be efficient and not generate costs that can be equated with waste. To achieve this, assembly planning is important to ensure methods for structuring and designing processes within an assembly system and the assembly line. The goal of assembly planning is to keep assembly costs as low as possible. Only in this way can a company become or remain competitive in the long term. The alignment should include the following points:
- Flexible system in terms of product and extensions
- Reusability of the system through standardized parts for subsequent use
- Use of standardized parts and modular principles
- Reduction of assembly costs in the areas of personnel and investments
- Planning of parts ordering and parts supply
- Achievement of the planned number of pieces in a short time
The 5 steps of assembly planning
Regardless of the particular products, assembly planning has a fixed structure. The most important points are:
Here, goals are set, a situation analysis is conducted, tasks are delineated, and the time required for the project is determined.
2. Rough planning
Work processes are defined and the assembly structure is developed by segmentation, the necessary hall space is determined, the personnel requirements are planned and the project costing and profitability calculation are carried out.
3. Detailed planning
The overall system is worked out in detail, a schedule is drawn up, the invitation to tender is carried out, the deployment of personnel is planned and the proof of economic viability is checked.
In this step, the procurements are arranged, the workstations are designed, the personnel are trained, the assembly system is installed and the documentation is prepared. In addition, the rehearsal takes place.
5. Production start-up
The system start-up is analyzed, errors are eliminated, documentation is corrected and acceptance is performed.
Do you need assistance in planning your installation?
Our assembly planning is carried out in compliance with established standards such as VDI 6026, allowing you to remain competitive and easily cope with increasing product diversity and market volatility.
Your contact person
Dr. Florian Bross