Title: Intelligent Seat model recognizing system

Chapter 1: Introduction

1. Objective

The objective of this experiment is to develop an artificial intelligent system in

order to recognize the car seat fram model in the line assembly. This is due to
the problem that occur where by applying this system it will reduce it and
improve the production of the car seat. Besides that, we will improve the cycle
time for the car seat frame assembly process.

2. Brief Introduction

The manufacturing process in which parts (usually interchangeable parts)

are added to a product in a sequential manner using optimum planned logistics
to create a finished product much faster than with handcrafting-type methods is
called an assembly line. It become famous when Ford Motor Company develop
it between 1908 and 1915 in the following decade through the social
development of mass production, such as the affordability of the Ford Model T
and the introduction of high wages for Ford workers. Ford was the first
company to build large factories around the assembly line concept.

Operator do the assembly

process
The purpose of assembly lines is designed for a sequential organization of
workers, tools or machines, and parts.

Laser welding robot

on the body-assembly line

The motion of workers is minimized to the extent possible. The parts or

assemblies are control or manage either by conveyors or motorized vehicles
such as forklifts, or gravity, with no manual trucking. Heavy lifting is done by
machines such as overhead cranes or forklifts. Usually, each worker is
performs one simple operation.

According to Henry Ford, there are three principles of assembly where are:

a) Place the tools and the men in the sequence of the operation so
that each component part shall travel the least possible distance
while in the process of finishing.
b) Use work slides or some other form of carrier so that when a
workman completes his operation, he drops the part always in
the same place--which place must always be the most
convenient place to his hand--and if possible have gravity carry
the part to the next workman for his operation.
c) Use sliding assembling lines by which the parts to be assembled
are delivered at convenient distances.
A car seat is the chair used in automobiles. Most car seats are made from inexpensive
but durable material in order to withstand as much use as possible. In Fuji car seat line
assembly, the operator need to choose the part for the car seat manually that come to
their station where it is depend on the type of the car seat. Before all the part being
assemble to become one complete seat, the small parts are assemble at subassembly
line. After the small part completely assembled, it is bring to the car seat frame line
assembly in order to assemble it become one car seat. So, this has led the operators
forced to use more energy because not only assemble the small part, but they had to
choose the small part that same type of the seats that come to their station. A car seat is
the chair used in automobiles. Most car seats are made from inexpensive but durable
material in order to withstand as much use as possible. Assembly block diagram
shown below:
3. Purpose

The purpose of our project is, to reduce the work that have been done of the
operator since they need to find the type of the small part that are same with the
seat frame type that come to their station. So, in order to reduce this problem,
we done improvement in the line assembly by applying the artificial intelligent
system such as fuzzy logic, and artificial neural network (but we will use
knowledge base).
Chapter 2: System

As mentioned in previous chapter, the system designed is to give intelligence to the system
especially in deciding a program that going to use for clamping and welding process
according to specifics seat frame grade and model.

2.1 Flowchart

Below is the overall flow chart of the system.

Below is the system choosing program flowchart.

2.2 Explanation

In Fuji Seats Malaysia Sdn Bhd, every seat frame has its different design and welding
point according to every specified model. It means that every seat model has it specific
designs and welding point area.

According to the flow chart, the system starts when the operator placed the seat frame
manually into jig. As mentioned, every seat model has its special design. So that, the jig is
designed consist with the sensor located in specific area that can differentiate and recognized
the seats design and model. After the sensor detect the frame model, the system then will
search the data in the data base. The system will proceed by selecting the setting for that
model if the sensor detected as the frame placed into jig. If not, the operator needs to re-place
the frame into the jig until the system recognized the seat model. The system then will
proceed if the sensor detects the seat model by choosing the setting for next process. After the
setting choose, the system then proceed to choose the setting for clamping and welding
process for the model that already recognized by system. After the system executes the data,
the machine then will clamped and welding the frame as data choose. After the process
finished, the jig will release the clamped and the seat frame will take out from jig manually by
an operator.

To assemble next seat frame but with different model than previous model, the
operator didn’t have to reset the system because the system will recognized the seat model
and grade by itself without human control.
2.3 Diagram

Diagram shows the layout of seat frame production line. As shown, it is consist with storage
area, seat assembly line, sub-assembly line, seat frame assembly line and rework area. The
device that designed will be implemented into seat frame assembly line. Seat frame assembly
line is the section where all parts from sub-assembly line were combined and weld. Sub-
assembly line basically including welding and combined raw material into seat frame sub
component. The finishes good from sub-assembly line then will supply to seat frame
assembly line from fabricate seats according to production model sequence. The finish
product from seat frame then will follows rework process before supply to seat assembly line.
Chapter 3: Simulation

All sources including coding, working simulation and project file can be seen in the report
CD.

3.1 Method

START (J) CLAMP (K) WELDING (L)

Figure 3.1.1: Station Figure

At Station (J) At Station (K) At Station (L)

MODEL
(RFID CODE) (RFID CODE) (RFID CODE)
Viva Low
A = 4473 (T) A + J = 4475 (F) F + K = 4477 (M)
Grade
Viva High
B = 4474 (V) B + J = 4476 (G) G + K = 4478 (N)
Grade
MyVi Low
C = 5473 (Q) C + J = 5475 (H) H + K = 5477 (R)
Grade
MyVi High
D = 5474 (S) D + J = 5476 (I) I + K = 5478 (P)
Grade
Alza E = 9871 (V) E + J = 9872 (Z) Z + K = 9873 (Q)

Table 3.1.1: RFID code for each model

There are 5 type of seat frame that can be recognize by this system. They are:

(A) Viva low grade

(B) Viva high grade
(C) MyVi low grade
(D) Myvi high grade
(E) Alza

As being explained by the previous chapter, this system will intelligently detect
the type of the seat frame that being inserted into the starting point (J). Then it
will intelligently change the clamping and welding point according to the
inserted seat frame type. Basically, this system will move from the starting
point to the clamping point and lastly to the welding point. To differentiate
each of this different point, when the seat frame had already passed each of the
point, the RFID code will be modified. This is because, if there are any defect
occur in one of this 3 point, the system can intelligently reinserted the seat
frame to the specific point (where the defect occur) without having to go
through all the previous station. This will reduce production time and it also
will increase productivity.

At station J, the RFID sticker on the seat frame will be scanned and analyzed
by the station. If the output is just like the column J on the table 3.1.1 it means
that each of the model does not going through any of the station yet, the
clamping and welding point will be assign according to the setting for each of
the model. But if the output is just like column K and column L in the table, the
clamping and welding point will be different according to each of the model
respectively. By doing this, the system can know the specific clamping and
welding point that each and every model need without any problems.

The AI of this system is based on Knowledge based system. It depends on the

ruled based expert system. Basically we have 2 principal ways which rules are
executed. The principal are:

a. Forward chaining
b. Backward chaining.

But in this project, we will use forward chaining as the main principal for our
systems. Before building the forward chaining structure, we need to create
inference chain for all data that we have.

Inference Chain
 Example of the cycle that occur inside of this system:

DATABASE DATABASE DATABASE

T J F T J F T J F

K Q H K Q H K Q H

M A M C A M

Knowledge Based Knowledge Based Knowledge Based CYCLE 1

F&K=M F&K=M F&K=M

A&J=F A&J=F A&J=F

A =T A =T A =T

C=Q C=Q C=Q

DATABASE

T J F

K Q H

C A M
Knowledge Based

F&K=M

A&J=F

A =T

C=Q

To simulate all of this theory, we had developed a simulation using Visual

Basic 6.0. In this simulation, we had produced the GUI (graphic user interface)
for controlling the output and input of the system. Below are the main
interfaces for the system.

G
B

C
H
D

Figure 3.1.2: Main GUI

A
= RFID code being scanned in this section
B = Station display whether:
 a. Start (J)
b. Clamp (K)
c. Welding (L)

= Model type whether:

C
a. Viva
b. MyVi
c. Alza

D = Grade of the seat frame, whether:

a. High
b. Low

E = Determine the clamping point for specified model

F = Determine the welding point for specified model

G = Button to start the operation after the RFID code being inserter into the “A”

H = Image display of the model and determining eheter the model is valid or not
in the database

Simulation

1. Simulation output for “low” grade seat frame

2. Simulation output for “High” grade seat frame

3. Simulation output for seat frame that already past J (starting) station

4. Simulation output for seat frame that already pass K (clamping) station
5. Simulation output for the invalid model in the database

6. Complete list of clamping and welding point

 MODEL Clamping Point Welding Point
Viva Low
1,2,3 1,2,3
Grade
Viva High
1,2,3,4,5 1,2,3,4,5
Grade
MyVi Low
2,3,4 4,5,6
Grade
MyVi High
2,3,4,7,8 4 , 5 , 6 , 9 , 10
Grade
1,2,3,4,5,6 1,2,3,4,5,6,7,
Alza
,7,8,9 8,9

7. Visual basic button coding

Private Sub Command1_Click() Case 4476 Case 5477

Value = rfid station = "Clamping" station = "Welding"
Select Case rfid jenis = "Viva" jenis = "MyVi"
Case 4473 grade = "High" grade = "Low"
station = "Start" clamp = "1 , 2 , 3 , 4 , 5" clamp = "Done"
jenis = "Viva" welding = "1 , 2 , 3 , 4 , 5" welding = "4 , 5 , 6"
grade = "Low" gambar = LoadPicture("image\vivaH.jpg") gambar = LoadPicture("image\MyviL.jpg")
clamp = "1 , 2 , 3"
welding = "1 , 2 , 3"
Case 5475 Case 5478
gambar = LoadPicture("image\vivaL.jpg")
station = "Clamping" station = "Welding"
jenis = "MyVi" jenis = "MyVi"
Case 4474 grade = "Low" grade = "High"
station = "Start" clamp = "2 , 3 , 4" clamp = "Done"
jenis = "Viva" welding = "4 , 5 , 6" welding = "4 , 5 , 6 , 9 , 10"
grade = "High" gambar = LoadPicture("image\MyviL.jpg") gambar = LoadPicture("image\MyviH.jpg")
clamp = "1 , 2 , 3 , 4 , 5"
welding = "1 , 2 , 3 , 4 , 5" Case 9873
Case 5476
gambar = LoadPicture("image\vivaH.jpg") station = "Welding"
station = "Clamping"
Chapter 2: System jenis = "MyVi"
jenis = "Alza"
grade = "High"
Case 5473 grade = "High"
clamp = "Done"
station = "Start" clamp = "2 , 3 , 4 , 7 , 8"
1. Flow Chart
jenis = "MyVi" welding = "4 , 5 , 6 , 9 , 10"
welding = "1 , 2 , 3 , 4 , 5 , 6 , 7 , 8, 9"
gambar = LoadPicture("image\AlzaH.jpg")
grade = "Low" gambar = LoadPicture("image\MyviH.jpg")
2. Explaination
clamp = "2 , 3 , 4"
welding =3."4 , 5Diagram
, 6" Case Else
Case 9872
gambar = LoadPicture("image\MyviL.jpg") station = "Error"
station = "Clamping"
jenis = "Error"
jenis = "Alza"
grade = "Error"
Case 5474 grade = "High"
clamp = "Error"
station = "Start" clamp = "1 , 2 , 3 , 4 , 5 , 6 , 7 , 8, 9"
welding = "Error"
jenis = "MyVi" welding = "1 , 2 , 3 , 4 , 5 , 6 , 7 , 8, 9"
Chapter
grade = "High" 3: Result gambar = LoadPicture("image\AlzaH.jpg")
gambar = LoadPicture("image\error.jpg")
MsgBox "Model NOT FOUND!", vbExclamation,
clamp = "2 , 3 , 4 , 7 , 8"
"Error"
welding = "4 , 5 , 6 , 9 , 10" Case 4477
gambar =1. Stimulation End Select
LoadPicture("image\MyviH.jpg") station = "Welding" End Sub
jenis = "Viva"
2. Video Basic
Case 9871 grade = "Low"
station =3.
"Start"Result clamp = "Done"
jenis = "Alza" welding = "1 , 2 , 3"
grade = "High" gambar = LoadPicture("image\vivaL.jpg")
clamp = "1 , 2 , 3 , 4 , 5 , 6 , 7 , 8, 9"
welding = "1 , 2 , 3 , 4 , 5 , 6 , 7 , 8, 9"
gambar = LoadPicture("image\AlzaH.jpg") Case 4478
station = "Welding"
Chapter 4: Conclusion
Case 4475 jenis = "Viva"
station = "Clamping" grade = "High"
clamp = "Done"
1. Conclusion
jenis = "Viva"
grade = "Low" welding = "1 , 2 , 3 , 4 , 5"
clamp = "1 , 2 , 3"
welding = "1 , 2 , 3"
 From the result, we confirm that with this system, the assembly process for the car seat
will become faster and will reduce less errors or mistakes. The system also will
improved other thing such as reduce cycle time and improve the quality of the
assembly. The number of labour also will be reduce due to this system because all the
part from the subassembly will be choose by the system and it automaically do the
assembly process without help from operator.

2. Recommendation
1. Improved the system detection.
2. Include the placement of frame that manually do by the operator now, in the
system so the assembly line is fully done by the system.
3. Improved selection program for different type of car seat frame.
4. Improved the assembly time of key workstation.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

 FACULTY OF MANUFACTURING ENGINEERING
BACHELOR OF MANUFACTURING ENGINEERING

(ROBOTIC & AUTOMATION)

4-BMFA/2

ARTIFICIAL INTELLIGENCE
(BMFA 4423)

PROJECT : Intelligent Seat model recognizing system

PREPARED BY:

MUHAMMAD SYAHMI BIN MOHD HASAN B050710038

MUHAMMAD SYAFIQ BIN SAMSUDIN B050710150

MOHD HAFIZULLAH BIN HAMZAH B050810163

ZUL AZRI BIN ZAINAL B050810123

PREPARED FOR:

MOHD HISHAM BIN NORDIN