State-of-the-art assembly planning​

We increase the flexibility and efficiency of your assembly

Assembly planning where every move is perfect

The goal in assembly planning consulting 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 that 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.

Challenges in assembly planning

Automation, the Industrial Internet of Things (IIoT), robotics, cloud computing and more… technology is advancing at a rapid pace, and most manufacturers are struggling to keep up, let alone stay ahead. By the time many IT departments have gone through the process of researching, approving, purchasing and installing new technology, a faster and more agile solution may have already emerged.

Current trends around the assembly

Our assembly planning consulting 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 particular workpiece to a particular 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
assembly planning
Assembly Planning

The 5 steps of assembly planning

Regardless of the particular products, assembly planning has a fixed structure. The most important points are:

1. Task

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, personnel requirements are planned and project costing and profitability calculations are carried out.

3. Detail 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.

4. Realization

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.

Assembly systems planning

Leave nothing to chance when it comes to assembly planning. Let us implement it together to make assembly processes more flexible, adaptable and nimble. We plan in compliance with established standards such as VDI 6026, so that you remain competitive and can easily cope with the increasing product diversity and market volatility. We at Bross & Partner would like to support you competently with our many years of experience.

Your contact person

Dr. Florian Bross