The automation of production lines is primarily focused on minimising machine loading time, which is usually a bottleneck in the production process. The optimization of manual positions, where workers manually assemble or insert components, is the fastest way to obtain a higher OEE score. Another goal of automation is decreasing the number of workers operating the machines. When constructing a production line, certain ergonomic and safety standards need to be met in order to ensure safe working environment and avoid worker injuries.
For this thesis, we constructed a semi-automated line for a new generation of aluminium differential cases. The thesis presents main reasons for automation in order for the company to stay competitive in the global market. The analysis of the existing situation showed that the goals connected to OEE had not been met. We decided to change the production of the new generation of differential cases and thus minimise bottlenecks in the production process. We tried to design a new production line, which, due to a big demand, will be used for two generations of differential cases simultaneously. As the same line will be used to produce different products, we decided against a fully automated line. Due to space limitations, we were unable to design a completely new line for the new generation of differential cases. Furthermore, this would mean significant adjustments for the current generation and new costs in the near future.
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