Manufacturing System and Process Development for Vehicle Assembly
1st Edition
Published on 30. December 2017
358 pages
978-0-7680-8347-7 (ISBN)
Available for download
Description
The evolution and execution of automotive manufacturing are explored in this fundamental manual. It is an excellent reference for entry level manufacturing engineers and also serves as a training guide for nonmanufacturing professionals. The book covers the major areas of vehicle assembly manufacturing and addresses common approaches and procedures of the development process.Having held positions as both a University Professor and as a Lead Engineering Specialist in industry, the author draws on his experience in both theory and application to fill the gap between academic research and industrial practices. This concisely written, comprehensive review discusses the sophisticated principles and concepts of automotive manufacturing from development to applications and includes: 250 illustrations and 90 tables.End-of-chapter review questions.Research topics for in-depth case studies, literature reviews, and/or course projects.Analytical problems for additional practice.Directly extracted and summarized from automotive manufacturing practices, this book serves as an essential manual. The subject is complemented by the author's first book, Automotive Vehicle Assembly Processes and Operations Management, which provides even greater depth to the complex endeavor of modern automotive manufacturing.
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Eric Walter | Richard Walter
Manufacturing System and Process Development for Vehicle Assembly
Book
12/2017
SAE International
€144.10
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Content
- Intro
- _GoBack
- Preface
- I.1 Approach
- I.2 Organization and Content
- Acknowledgment
- Introduction to Automotive Product Engineering
- 1.1 Vehicle Development Management
- 1.1.1 Product Engineering and Development
- 1.1.2 Engineering Change Management
- 1.1.3 Lifecycle Analysis in Development
- 1.1.4 PLM Principle and Applications
- 1.2 Architectures of Passenger Vehicles
- 1.2.1 Passenger Vehicle Overview
- 1.2.2 Vehicle Body Architectures
- 1.2.3 Sheet Metal Parts
- 1.3 Materials for Vehicle Body
- 1.3.1 Conventional and New Steels
- 1.3.2 Non-ferrous Metals
- 1.3.3 Nonmetallic Materials
- 1.3.4 Considerations in Material Selection
- 1.4 Exercises
- 1.4.1 Review Questions
- 1.4.2 Research Topics
- References
- Methodology of Assembly System Development
- 2.1 System Development Procedure
- 2.1.1 Manufacturing Development
- 2.1.2 Development Standardization
- 2.2 Main Approaches for Development
- 2.2.1 Systems Engineering in Development
- 2.2.2 Design for Manufacturing
- 2.2.3 Lean Manufacturing
- 2.3 Project Management for Development
- 2.3.1 Project Management Overview
- 2.3.2 Alternative Selection
- 2.3.3 Project Planning
- 2.3.4 Project Execution
- 2.4 Challenges and Advance
- 2.4.1 System Intelligence
- 2.4.2 Virtual Development
- 2.4.3 Additive Manufacturing Technology
- 2.5 Exercises
- 2.5.1 Review Questions
- 2.5.2 Research Topics
- References
- Analyses of New Manufacturing Systems
- 3.1 System Reliability
- 3.1.1 Reliability Fundamentals
- 3.1.2 Analysis of Workstation Reliability
- 3.1.3 Analysis of Assembly Line Reliability
- 3.2 Manufacturing Flexibility
- 3.2.1 Overview of Manufacturing Flexibility
- 3.2.2 Challenges to Manufacturing Flexibility
- 3.2.3 Discussion on Assembly System Flexibility
- 3.2.4 Design for Manufacturing Flexibility
- 3.3 Other Capabilities of Assembly Systems
- 3.3.1 Cycle Time
- 3.3.2 Product Quality
- 3.3.3 System Throughput
- 3.4 Economic Analysis of Development
- 3.4.1 Economic Comparison of Alternatives
- 3.4.2 Assessment of New Manufacturing Systems
- 3.5 Exercises
- 3.5.1 Review Questions
- 3.5.2 Research Topics
- 3.5.3 Analysis Problems
- References
- Design of Vehicle Assembly Systems
- 4.1 Considerations in System Design
- 4.1.1 Requirements of Manufacturing System
- 4.1.2 Characteristics of Assembly Lines
- 4.2 Application of Hierarchical Modeling
- 4.2.1 Product Assembly Architecture
- 4.2.2 Overall Development Procedure
- 4.2.3 First Step: To Design System Flow
- 4.2.4 Second Step: To Configure Assembly Lines
- 4.2.5 Considerations in System Development
- 4.3 Development of System Layouts
- 4.3.1 Vehicle Assembly Layouts
- 4.3.2 Considerations in Layout Development
- 4.3.3 Dimensions of Assembly Systems
- 4.4 Exercises
- 4.4.1 Review Questions
- 4.4.2 Research Topics
- References
- Process Planning for Vehicle Assembly
- 5.1 Process Engineering for Vehicle Assembly
- 5.1.1 Assembly Process Planning Overview
- 5.1.2 Considerations in Process Planning
- 5.2 Process Planning of Workstations
- 5.2.1 Process Task Assignments
- 5.2.2 Operation Time Study
- 5.2.3 Efficiency of Manpower Utilization
- 5.3 Technical Focuses in Process Planning
- 5.3.1 Operation Balance
- 5.3.2 Process Robustness
- 5.3.3 Process Flexibility
- 5.4 Proactive Planning using FMEA
- 5.4.1 FMEA Principle
- 5.4.2 P-FMEA Development
- 5.4.3 M-FMEA Characteristics
- 5.5 Exercises
- 5.5.1 Review Questions
- 5.5.2 Research Topics
- 5.5.3 Analysis Problems
- References
- Automatic and Manual Operations
- 6.1 Manufacturing Automation
- 6.1.1 Automation Overview
- 6.1.2 Control Logic of Operations
- 6.1.3 Applications of Sensors
- 6.2 Robotic Applications
- 6.2.1 Industrial Robot Overview
- 6.2.2 Robots in Vehicle Assembly
- 6.2.3 Safety Considerations for Robotic Applications
- 6.2.4 Advance-Collaborative Robots
- 6.3 Considerations for Manual Operations
- 6.3.1 Characteristics of Manual Operations
- 6.3.2 Worker Safety Assurance
- 6.3.3 Ergonomic Considerations
- 6.4 Exercises
- 6.4.1 Review Questions
- 6.4.2 Research Topics
- References
- Design and Arrangement of Supportive Functions
- 7.1 System Buffering
- 7.1.1 Buffers in Manufacturing Systems
- 7.1.2 Influences of Buffers on Throughput
- 7.1.3 Buffer Planning
- 7.2 Inbound Logistics
- 7.2.1 Delivery of Incoming Materials and Parts
- 7.2.2 Shipping Racks and Transportation
- 7.2.3 Part and WIP Tracking
- 7.2.4 Facilities Functionality
- 7.3 Part and WIP Transfer in Assembly Operations
- 7.3.1 Part Delivery Conveyors
- 7.3.2 Robotic Material Handling
- 7.3.3 Large Conveyance Systems
- 7.4 Build-in Quality Assurance
- 7.4.1 Quality Assurance Planning
- 7.4.2 Rework and Pull-off Functions
- 7.4.3 Cost Considerations in Quality Assurance
- 7.5 Exercises
- 7.5.1 Review Questions
- 7.5.2 Research Topics
- References
- Management of Tooling Development
- 8.1 Assembly Tooling Development
- 8.1.1 Functionality of Assembly Tooling
- 8.1.2 Development of Special Tooling
- 8.1.3 Tooling Flexibility
- 8.2 PLP Principles and Applications
- 8.2.1 GD&T for Automotive Assembly
- 8.2.2 Part Locating Principles
- 8.2.3 Considerations for Locating Compliant Parts
- 8.3 Fixture Functional Design
- 8.3.1 Fixture Components and Units
- 8.3.2 Fixture Configurations
- 8.4 Fixture Dimensional Assurance
- 8.4.1 Principle and Procedure
- 8.4.2 Dimensional Accuracy Certification
- 8.4.3 Functional Repeatability Certification
- 8.5 Exercises
- 8.5.1 Review Questions
- 8.5.2 Research Topics
- References
- About the Author
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