Chng 7

h thng lp rp thay i v cu hnh li

B. Lotter1 and H-P. Wiendahl2 Tm tt: Lp rp cng nghip l i tng thay i sn phm nhanh chng, tng s lng, bin i kiu dng sn phm v ko di cc k hoch ngn hn ca khch hng. Do cng vic bng tay chim thi gian tng i cao, p lc v chi ph t cc nc c mc lng thp cn kh cao. Nhng thch thc ny c th c p ng c hiu qu, tuy nhin, thng qua mt mu gii thiu v cch tip cn hp l lp rp, cng ngh lp rp linh hot cao v cc nhn vin nng lc chuyn mn. Ty thuc vo s phc tp sn phm, a dng v hnh dng v t l u ra c mt s khi nim c sn, nm gia cc nhu cu cnh tranh v nng sut v tnh linh hot. Chng ny m t Cc tnh nng chnh ca lp rp th cng, t ng v lp rp kt hp vi mt s ch c bit v tnh linh hot v kh nng t chc sp xp li. Keywords Manual assembly, automated assembly, hybrid assembly, set-wise assembly, one-piece flow.

7.1 gii thiu

Lp rp cc sn phm trong cng nghip sn xut bt c lnh vc no cng chim t 15 n 70 % ca tng thi gian sn xut . Cng ngh lp rp hiu qu v th tuyt i quan trng. Kim sot mnh m s bin ng khi lng cng nh lin tc pht trin kiu dng ca sn phm c bit kh khn khc nhau. Do vng i sn phm ngn hn trn th trng, sn phm v bin i kiu dng ph thuc vo thnh phn lp rp mt h thng c mu nh nh vn u t v to iu kin hiu qu hot ng vi mt mc ln v kh nng thay i quy m ca qu trnh sn xut. Ngnh cng nghip s dng nhiu tng p ng nhng yu cu ny. Hnh 7.1 m t cc lnh vc s dng ba h thng lp rp quan trng nht: lp rp bng tay
1 2

Assembly Consultant, Germany University of Hannover, Germany 127

H.A. ElMaraghy (ed.), Changeable and Reconfigurable Manufacturing Systems, Springer 2009

128
high

B. Lotter and H-P. Wiendahl

variant

diversity
high

low

low

productivity

automated assembly hybrid assembly assembly

low

high

low

quantity

high

Fig. 7.1 Cc khu vc s dng khi nim qui trnh s dng, lp rp v t ng lai

, lp rp hn hp v lp rp t ng. C th thy rng ngy cng nhiu cc mc t ng ha lm tng nng sut; tuy nhin tnh linh hot v iu khin gim thiu s bin i a dng v hnh th. C hai sn phm v nhu cu th trng rt quan trng khi la chn mt m hnh lp rp. Trc ht, kch thc, trng lng v c cu cng nh thay i v s lng cc mt hng ca sn phm xc nh cc iu kin gii hn ca k thut. Hn na, h thng lp rp phi tun th mt s yu cu bao gm: thi gian bn hng d kin, s lng d kin ca chi tit cho mi n v thi gian cng nh nhu cu ca th trng m tt c cc bin th c cung cp theo tng phn nh v ch trong thi gian yu cu. Tng qut c th ni rng h thng lp rp c xy dng ban u vi cc thnh phn m-un. iu ny d dng hn nhiu hn so vi h thng sn xut, bi v cc c cu cn thit kt ni cc b phn thng t hn nhiu so vi nhng yu cu trong gia cng v qu trnh hnh thnh. iu ny p dng i vi chnh xc v cng ca khung my mc v thit b dn hng. Trong cc h thng lp rp cc b phn cn phi c cung cp, di chuyn c xu hng a dng, nhiu v nhy cm hn trong h thng sn xut khc. Trong qu trnh pht trin cc h thng lp rp cng nghip, c su hnh dng c bn c to ra p ng s a dng ca cc cng vic kt qu. Hnh 7.2 phn loi cc khi nim ny vo h thng lp rp cng (ch yu l t ng) v linh hot (ch yu l th cng). Hai nhm ny sau c phn loi thm theo sn lng (sn phm / gi) v s phc tp ca sn phm (th hin trong s nhng linh kin lp rp). S khc bit c bn gia hai nhm vi cc h thng t ng cng nhc, trng tm l thit k k thut, trong khi vi cc h thng hng dn s dng linh hot, b tr cng vic ca nhn vin chim u th. N c th c thy r trong hnh. 7,2 rng cc gii hn ca t l u ra cho mt h thng hng dn s dng l khong 720 sn phm mi gi, tng ng vi mt thi gian chu k ca nm giy. Trong so snh vi mt h thng t ng (vi ngoi l ca ci gi l t ng tc cao)

flexibility

manual assembly

flexible assembly 70 60 50 40 product complexity [number of parts/operations] 30 20 10 0

0 200 400 600 800 1000 1200 1400 1600 1800

one-piece-flow assembly manual flow assembly hybrid assembly

manual single place assembly output [piece/hour]

0 10 20 30 40 50 60 70 automated flow assembly automated single place assembly

rigid assembly

Fig. 7.2 Classification of assembly systems according to output and complexity

gii hn l 1800 sn phm / gi v do thi gian mt chu k ca hai giy. Yu t tip theo c xem xt lin quan n cc h thng l tnh linh hot ca h thng.

7.2 h thng lp rp th cng linh hot

c im ch yu ca lp rp th cng l con ngi vn hnh. Bng cch s dng tay kho lo, cc gic quan v tr thng minh cng vi s h tr, chng hn nh cc cng c, g lp v trang thit b, ng h o ..., ngi lao ng thc hin cc hot ng lp rp. T l sn lng ca ngi lao ng l ph thuc vo mt s yu t, chng hn nh thit k gn nh ca trm lm vic v mi trng xung quanh, v d, phng khch, nh sng. v.v.. Hn na, vic b tr khng gian lm vic cng ng mt vai tr quan trng. Cng vic lp rp nn c thc hin trong khu vc quan st ca ngi cng nhn m khng cn phi di chuyn u ca h v cao thp hn so vi tim. Chuyn ng lp i lp li, chng hn nh un cong v thng ngi ln cn phi trnh. Lp rp trong cc khng gian lm vic chnh xc cho php mt mc cao hiu qu thng qua vic tip cn d dng. Hn na, n ngn chn s mt mi v cc li lp rp, thch hp cho cc ngi lao ng ln tui hoc c hiu sut lao ng thp. Tuy nhin, n c a vo xem xt trng thi lao ng ng c mt khng gian lm vic tng i nh v do ch thch hp lp rp cc sn phm nh vi phc tp ti thiu. Sn phm phc tp phi c lp rp hoc bng cch chia cc ni dung cng vic vo mt s my trm lin kt hoc bng cch hon thnh n trn mt my trm vi dng lp rp nh vy gi l lp rp linh hot.

7.2.1 Tr m l p rp n v i thit lp d y chuy n l p rp linh hot

Thng thng cc chi tit c lp rp bng tay theo tng cp, l mt sn phm c lp rp hon chnh tng bc trc khi thc hin cng on tip theo. Ngc li, vi dy chuyn lp rp lp rp linh hot, phn u tin c lp rp thc hin cc cng vic tip theo (v d, 8, 12 hoc 16), sau l phn th hai v nh vy cho n khi phn cui cng. to iu kin thun li cho s lp li ca chuyn ng, cn b tr my trm vi s h tr ca hai bn xoay nh trong hnh. 7,3 khuyn khch s dng s b tr. Bn xoay 1 cha mt phn c s ca sn phm trong (18 trng hp trong ny), trong khi bn xoay 2 mang cc b phn c c gn kt vo cc phn c s trong thng linh hot s lng ln (y 6 phn P1 n P6) . Mi b phn c lp rp c th c lun chuyn vo v tr thun li nht (v tr c gi l ch ni) lin quan n phn c s. Li th ca s sp xp ny l s lp i lp li. Mt li th na l khong cch ngn tng t cho tt c cc b phn lp ghp. Thi gian cn thit chn v tr li cc cng c phn phi trong s cc b phn c bn c tm thy trn bn xoay 1, bi v chng ch c th lp ghp cho mi ln thc hin mt sn phm. Hn na, cc b phn ring l c cung cp chnh xc tng ng vi trnh t lp rp v do cht lng lp ghp cng tng. So vi cc lp ghp tng cp, thi gian lp rp hon chnh c th c gim khong 30-50%. Tuy nhin, nhng gii hn ca khi nim ny t c khi cc bin i hnh dng kch thc, s lng hoc cc b phn, bn xoay yu cu tr nn qu ln qun l. Khi nim ny tp trung c hiu qu nh lp rp c th lm gim s di chuyn ca cng nhn. Tnh linh hot ca cc bin th sn phm c th t c thng qua bn xoay thit lp trc , m cng c th nhanh chng thay i. Khi lng

press assembly fixture P5 P4 P3 P2 P1 turntable 2 for 6 bins (bulk ware) P6 turntable 1 for 18 produ cts

joint position

m m
placement final product

hnh. 7.3 Lp rp trm khn

ngoan trnh t thit lp cho mt componentry in

s linh hot cng d dng kim sot bng cch ko di hoc rt ngn lch trnh hot ng hng ngy. Ni tm li iu cn ch y l s cn i mt t l ln ca khng gian lp rp cc thnh phn c th c ti s dng. thit lp cho sn phm khc, ch c sn phm lp rp mi cn c thay i.

7.2.2 Trm lp rp n theo nguyn tc mt phn ca qui trnh sn xut

lp rp cc sn phm vi mt s lng ln cc b phn v cc bin th sn phm trong cc c kch thc, th cn thit phi c nhiu thnh phn khc nhau v cc cng c c sn . Nu lp rp din ra ti mt my trm iu ny dn n cc vn v khng gian . Mt gii php hiu qu cho loi cng vic lp rp duy nht trm lp rp, theo cc nguyn tc mt phn ca dy chuyn sn xut . Trong trng hp ny , ngi vn hnh di chuyn cng vi b phn cung cp theo mt lot cc thng cung ng v hon thnh mt phn c s mnh mnh c c sn phm hon chnh . V vy nh tn xut , mt trong nhng sn phm ti mt thi im chy qua cc trm lp rp c nhn . Nh mt v d ca loi hnh ny ca my trm , hnh . 7,4 minh ha mt thit k bng cch s dng mt bng chuyn dn hng bng bi vi mt b hnh bn nguyt. b lp rp nh vy gi l tm trt , khi t trn bng chuyn dn hng bng bi c th d dng t di chuyn ti lui xung quanh ton b bn vng trn. Tm trt t trn bn xoay , m trn gi cc b phn cho php ti u cho ngi iu khin v sn phm . Thnh phn v cc cng c c cung cp t pha bn ngoi ca h thng bng cch bm li hoc thay i thng s lng ln . Cch b tr ca cc thng tng ng vi trnh t lp rp . Ty thuc vo kch thc ca cc thnh phn hoc bao gi , ln n 50 thng c th c t pha bn ngoi ca my trm lm vic , tt c chng nm thp hn tim ca ngi iu khin .
parts supply (bulk ware)
assembly sled part carrier

ball guide rail

base parts

final products

station with parts supply device for product variant A

changeable parts supply device for product variant B

Fig. 7.4 a,b Mt mnh dng lp rp trm thay i thit b cung cp cho cc b phn b

Tt c nhng g cn thit thay i v tr cng vic l mt chuyn ng c th ti thiu , theo khu vc lm vic vn cn trong khu vc quan st ca ngi lao ng. Kh nng thay i ca khi nim ny my trm c lin quan n cc bin th ca sn phm t c bng cch loi b cc thit b phn cung cp ton b t bng ti dn hng bng bi v thay th n vi mt s khc c thit lp . Thi gian chuyn i yu cu t mt trong nhng sn phm mi l cc k ngn . Tuy nhin, s linh hot khi lng khng ln hn so vi lp rp thit lp linh hot.

7.2.3 Nhiu trm lp rp theo nguyn tc mt phn qui trnh sn xut

Nu vic thay i mu m sn phm tip tc gia tng v s lng sn phm tng ln n khong 100.000 sn phm / nm v rt nhiu giao hng t 1 n 100 chic c yu cu, sau l mt gii php chng hn nh biu th trong hnh . 7.4 khng cn nng lc p ng . Cc b phn khc nhau, c bit c cung cp chnh xc ph hp vi kch thc l hng yu cu. Trong trng hp ny, gii php r rng l tch vic cung cp cc mt hng bin th ph thuc t cc phin bn c lp nh minh ha trong v d sau y . Cc sn phm c lp rp mt mch iu khin thit b . Vi din tch c s ca 80 mm x 160 mm v trng lng khong 2,5 kg , n bao gm 48 phn khc nhau . Tm trong s cc thnh phn hoc n v c lp trc xc nh cc thit k bin th v 40 ngi trong s h l mt phn bin th trung lp . Cc c kch thc dao ng gia 10 v 50 sn phm.
commissioning area

a
variant determining items (picked to light)

packing shipping

PC + printer

entrance

multipart part carrier ball guide rail

Fig. 7.5 Assembly system for highly variable products

Cc h thng lp rp c thit k cho vic ny (Hnh 7.5) bao gm hai phn: khu vc vn hnh v dy chuyn lp rp thc t . Cc thnh phn khc nhau ph thuc c lu tr trong khu vc vn hnh, c t chc nh mt siu th , trong khi cc b phn trung lp bin th c cung cp cng dy chuyn lp rp s dng . Dy chuyn sn xut c hon thnh trong cc bc sau: khu vc vn hnh c trang b vi mt my tnh v mt my in . Ngi lao ng di chuyn cc sn phm lp rp hon chnh, kim tra sn phm tr v v t n vo cc dy chuyn ng gi . Ngi tip sau gi th t tip theo trn my tnh , in ln lt mt nhn nhn dng , m sau c t trn cc bng ti ti mt im xc nh trc. H thng " chn vi nh sng" cng c kch hot . N bao gm hin th nh sng trn mi hp ch ra cho ngi cng nhn cc b phn cn c chn v t trn cc bng ti mt phn trng cho cc bin th tip theo . c c khng gian cn thit cho cc b phn , B phn di chuyn c ghp trc sau hoc mt phn kt hp c bng ti vn chuyn nh m t trong hnh . 7.6. di chuyn mt phn c s hoc vt c nh lp rp t trn , c th hin trong hnh . 7.6a trong khi vic ni rng di chuyn c minh ha trong hnh . 7.6b . Nhng tm di chuyn cng gi nhng mn ph thuc bin th trong mt loi u vo v trong trng hp ny c phn vng cho sn phm . Nu sn phm l phc tp hn v c phn bin th c th hn cn phi c gn kt , th ta c th kt hp thm nh trong hnh . 7.6c . Ngi cng nhn ti ni bng ti vn chuyn s thm cc b phn trong cc ti ng trn cc tm di chuyn. Mt phn c ly ra t hp tng ng trong khu vc lm vic, mn hnh hin th nh sng i ra . Khi tt c

a part carrier with base part holder

part carrier one side extended with variant determining items

Fig. 7.6 ac Part carrier sys- tem for versatile products assembly

part carrier both side extended with variant determining items

n tt , di chuyn c c a tr li dy chuyn lp rp. Sau , ngi cng nhn sp xp li cc tm di chuyn ln bng ti v ghp chng li ph hp vi dng sn phm s c lp rp. Khi nim ny c tnh linh hot cao nh nhau c hai u lin quan n s lng tm cng nh s lng ca cc bin th . Cc thnh phn thc hin cng v cng kh dng. Hn na, n c th d dng ni ghp li , bi v chng c tnh linh hot cao v c ch to theo tiu chun. Trong khi nim v tm di chuyn cc bin th t c bng cch thay i mt phn . T l sn xut c th c thay i bng cch b tr mt, hai hoc ba nhn vin trong vng trn bn trong ca h thng.

7.3 H thng lp rp linh hot

Trong hnh . 7.2, c th thy rng mt t l u ra trn 720 ming / gi i hi mt h thng t ng . Dy chuyn lp rp lin tc l rt thch hp cho cc sn phm lp rp vi din tch b mt ln n khong 300 400 mm v nng khong 20 kg . Hu nh tt c cc dy chuyn lp rp lin tc s dng cc m-un tiu chun ha c bn . Nhng c cu nn tng cho cc m-un c lp ghp bng vt, hn, hoc th nghim . Lin kt vi cc m-un c bn , cc hnh thc trm t ng . Cc m-un qu trnh ln lt bao gm cc sn phm nn tng c bn trung gian v khch hng hoc nhng th tc c trng . Cc m-un qu trnh c a vo cc trm t ng bng tay hoc bng cch s dng mt sn xp d hng , trong khi d liu v nng lng c chuyn thng qua kt ni phn mm . Do s di chuyn ca cc m-un qu trnh sa i h thng c th c hon thnh trong t hn mt gi , i khi i hi phi c t nht l mt vi pht . Ngc li , chuyn i mt h thng km linh hot c th mt t mt n mt tun . Hn na thnh phn c bn bao gm cc module s dng ring, m cng c th c tch hp vo h thng . Hnh 7.7 minh ha v d ca mt h thng c bn bao gm, trm gia cng, m-un kt ni, th cng v t ng hoc c th kt hp. Do chi ph vn tng i cao , khch hng quy nh rng cc h thng c th pht trin hoc thu nh vi nhu cu khc nhau trong vng i sn phm. Nh vy , giai on tng tc ca mt sn phm mi c th bt u vi mt h thng tng i nh , bao gm 1-2 my trm th cng v thit b t ng . iu ny s gip gim chi ph vn nht thit cho cc ngun lc trong phm vi gii hn qun l . Nu s lng sn xut pht trin tch cc trong thi gian sau , h thng lp rp c th thch nghi vi nhu cu ngy cng tng trong giai on m rng c m t trong hnh . 7.8.

Fig. 7.7 Modular system for linear transfer assembly lines (Courtesy Teamtechnik)

Fig. 7.8 Extension stages of linear transfer assembly lines (Courtesy Teamtechnik)

Mt khc , kch thc ca h thng cng c th c gim theo cng mt cch khi s lng ca sn phm gim trong giai on cui vng i ca n . Do vic xy dng tiu chun ca cc m-un , cc thnh phn h thng m sau khng phi u t chi ph lp rp th h tip theo ca sn phm . Tnh hay thay i i vi t l sn xut c m bo trong khi nim ny bng cch thay i t th cng sang cc trm t ng v / hoc thm hoc loi b trm . im bt li nm trong chi ph tng i cao i vi cc m-un qu trnh nu chng khng cn cn thit na . Ngoi ra nu thi gian tn ti ca sn phm ngn hn nhiu hn so vi gii hn k thut ca cc m-un vic ti s dng cc m-un s tr thnh vn .

7.4 H thng lp rp lai 7.4.1 c im

Nh gii thch, vi mt s lng ngy cng tng ca cc chi tit, cc my trm hon ton bng tay thng khng c nng lc. Trc khi bt u s dng mt gii php hon ton t ng , cn xem xt n s pha trn gia lp rp bng tay v lp rp t ng. y c gi l " lp rp lai ". Cc h thng lp rp lai l c s cho cc n v lp rp v / hoc sn phm , trong cc my trm t ng c kt hp vi my trm th cng, lin quan n s lng mnh , bin th a dng , nng sut v s linh hot m h thng lp rp bng tay v t ng c b tr thch hp, xem hnh . 7.1. im khi u cho vic lp k hoch mt h thng lp rp lai l lp rp th . T , t l thch hp nht gia cc nhim v t ng v th cng s c xc nh bng cch iu chnh cc mc t ng ha cho cc hot ng lp rp ring vi cng vic lp rp tng ng . Bng cch thay i s lng cng nhn lp rp trn cc my trm th cng, c mt mc cao ca tnh linh hot v s lng cc mnh . Thay i t ngt trong nhu cu c th d dng p ng . V d mt h thng lp rp vi bn la chn v t cc trm cng c th c ngi li vi ch hai nh khai thc thay v bn , do dn n gim 50 % trong t l sn xut . , V d , trong nhng ngy l ch c mt n t hng , h thng thm ch c th c vn hnh ch vi mt ngi . Sn lng sn phm sau s c khong 25% mc ti a u ra ca h thng c th . Mt li th na ca h thng lp rp lai l mc ban u ca t ng ha c th c thch nghi vi nhng thay i trong t l sn phm trong i sng ton b dch v bng cch s dng mt s giai on m rng . Ch khi ton b tim nng ca mt giai on cn kit , l cp tip theo ca phn m rng thc hin da trn s lng bn hng thc t . Cui cng nu nhu cu ca cc sn phm tip tc tng, c th b sung cho h thng vi cc trm lp rp lai tip theo. S nguy him ca mt khon u t xu , c bit l trong giai on u t ban u. Vi mt h thng lai , iu quan trng l lun lun c gng xy dng n bng cch s dng cc thnh phn sn phm trung gian , do tng t trng ca cc module h thng c th c ti s dng sau khi kt thc vng i sn phm. Bi v qu trnh th cng khng phi l qu trnh t ng thit lp tc cho cc trm vi chu k thi gian bin i ngu nhin ca cc trm th cng to ra s khng c vn . Tip theo, da trn cc v d c th , h thng lp rp lai s c tip tc tho lun .

7.4.2 V d ca h thng lp rp lai

Mt cng c kp c lp rp vi mt hot ng sn xut khong 2,5 triu sn phm/ nm. N bao gm 12 phn khc nhau , c th c kt hp vo nm nhm khc nhau

Cc nhim v quy hoch sau y c xc nh:

Thi gian hot ng ca h thng l 230 ngy / nm vi hai ca , mi ca by

gi.

Chi ph lp rp trn mt n v sn phm 0,30 USD. Thi gian hon vn u t khng qu 5 nm. C mt h thng lp rp t ng v mt lai ang c ln k hoch v so
snh vi nhau. i vi vic lp rp t ng , bng 80% s dng, vn u t ca 1,6 triu USD v lp rp n v vi chi ph 0,29 USD vi 2,5 triu chic / nm c xc nh. Cc k hoch cho cng ngh lp rp lai bao gm vic thc hin hai h thng . Tng vn u t c tnh theo 445 000 USD, mc s dng 90 % , v n v 0,245USD. Hnh 7,9 minh ha cc gii php c tm thy cho mt h thng lp rp lai v ba c th m rng giai on bao gm cc tc d liu u ra . Hnh 7,10 gii thch cc qui trnh cng vic trn mt trong nhng my trm lm vic c th . Cc ni dung cng vic ca giai on m rng u tin c phn chia gia my 'A' trm v my trm 'B' . Theo nguyn tc qui trnh linh hot, b tr trc sau vi 12 g lp rp , c ng b ha trong trm. Phn c s c cha trong mt palette. Trn my trm ' A' , 8-10 phn khc nhau c chn bng tay ty thuc vo cc bin th ca sn phm . Cc phn cn li c chuyn sang my trm 'B ' v tip tc di chuyn . y, ngi lao ng bng tay chn phn cn li

station A

station B

output in 14 hrs

extension stage 1 (1 person)

+ +

+ +

1,564 pieces

pallet magazine station A station B station C

extension stage 2 (2 persons)

+ +

+ +

3,124 pieces

pallet magazine 1 pallet magazine 2 buffer 1 station A

+ +

station B

buffer 2 station C
+ +

extension stage 3 (3 persons)

+ +

5,040 pieces

pallet magazine 1 pallet magazine 2

Fig. 7.9 Extension stages of a hybrid assembly system (example clamping tool)

station station A
automated station dynamic supply with turn table

station B station B
buffer automated stations

grip bin
P6

P5

P4

P3 P2 P1
T11

+
P7

automated station

P8

P9

P10

grip bin part carrier

base parts/ finished items

Fig. 7.10 Hybrid assembly system extension stage 1

cc b phn v ti cng mt thi gian chy cc qu trnh t ng. Sau khi hon thnh, ngi lao ng chuyn sang bng ti tr li my trm 'A' v c chuyn i 12 thnh phm. Chu trnh lp rp sau c khi ng li. T l u ra ca giai on m rng u tin trong mt ch thay i hai trong tng s 14 gi mi ngy lm vic l 1 564 sn phm. Khong 70% ca tng s ni dung cng vic c thc hin trn my trm 'A' v khong 30% my trm 'B'. Trong giai on m rng th hai (xem hnh 7.10) h thng c m rng thng qua mt trm lm vic thm 'C' (mt bn sao ca my trm 'A'). Kt qu l hai nhn vin khc s dng my trm 'B' l bt buc. Vi hai ca, t l sn lng tng 3 124 sn phm mi ngy. Trong giai on m rng th ba, mt s hot ng t my trm 'A' v 'C' cng vi mt nhn vin b sung c giao cho my trm 'B'. T l u ra ca h thng, vi hai ca tng 5040 sn phm mi ngy. tch ring cc my trm lm vic 'A' v 'B' v / hoc 'B' v 'C' b m ln k hoch. iu ny cho php vic trao i ca cc phn gia cc my trm. Vi nhu cu nng cao nng lc, h thng lp rp lai th hai cng c th c tng t nh vy thc hin trong giai on m rng khc nhau. Cc chi ph vn cng c thc hin trong giai on song song vi vic thc hin cc giai on m rng. V vy, i vi mt h thng trong giai on m rng u tin yu cu 127 000 USD giai on th hai m rng 54 000 USD giai on m rng th ba 41 500 USD. i vi mt h thng th hai, chi ph vn c th c d kin s tng t. Trong hnh. 7,11, xu hng ca cc chi ph lp rp nh l mt chc nng ca sn lng sn xut, cho c h thng hon ton t ng v h thng vi ba trm lai c so snh.

2.0
1.8 1.6 1.4 assembly costs [/piece] assembly automat

1.2 1.0 0.8 0.6 hybrid system 1 0.4 0.2 0.245 0.0 1 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 output [pieces/day]

hybrid system 2 0.290

Fig. 7.11 Comparison of assembly costs for automated vs. hybrid system (example)

Nhng li th c bn ca cc gii php lai l: tnh chi ph lp rp 0,245USD lun thp hn so vi h thng t ng , chi ph vn r rng thp hn, v trong trng hp ( thng xuyn quan st ) , ni t l sn xut khng ln vn u t l thp hn . Tng t nh phn tch cc hng mc lp rp khc ch ra rng v d ny khng l ngoi l . D liu trong by v d c s dng so snh kt qu lp rp t ng v lp rp lai . Cc d liu quy hoch c ch nh trong hnh . 7,12 . S dng cc gi tr tiu chun ha , c chi ph nhn s cng nh cc chi ph c nh v bin c xc nh thng qua chi ph lm vic chun. Ch c thi gian hot ng hng ngy khc nhau.
example item name parts [ ] 12 7 810 12 17 12 25 planned output [ pieces / year ] 2,500,000 2,200,000 2,850,000 500,000 1,500,000 2,300,000 950,000 working schedule [ hrs / day ] 15 15 14 14 22.5 14 15

1 2 3 4 5 6 7

electrical switch electric motor drill chuck (final assembly) water water boiler faucet

clamping tool planetary gear

Fig. 7.12 Product samples automated vs. hybrid assembly

250

variable costs (personnel) fixed costs

assembly unit cost [/hr] at maximum output

200

150

100

50

330

300

0 33

1
4 2 aut. 10 hyb. 2 2 aut. aut.

2
4 4 6 6 hyb. hyb. 2 2 aut. aut.

3
8 8 8 8 hyb. hyb.

4
10 2 10 6 2 aut. aut. 6 hyb. hyb. 0.48 0.48 2 2 aut. aut.

5
2 2 12 12 2 aut.

6
5 12 12 hyb. 2 2 aut.

7
4 16 hyb.

product

no. of variants operators/day assembly type assembly type cost per piece []

0.166 0.176 aut. hyb. 0.166 0.176

0.29 hyb. aut. 0.244 0.89 hyb. 0.88 hyb. aut. hyb. 0.244 0.89 0.88

0.153 0.151 0.153 0.151

0.17 0.153 0.49 0.17 0.153 0.49

0.62 0.43 0.62 0.43 0.29

Fig. 7.13 Comparison of assembly costs for seven different products

Hnh 7,13 cho thy cc chi ph lp rp tnh trong by v d , chia thnh chi ph c nh v bin . Cc chi ph ca h thng t ng ( ct bn tri ) c so snh vi chi ph ca cc gii php lai ( trong ct bn phi ) . Chi ph n v lp rp v s lng nhn vin trong giai on cng sut cui cng cng c hin th.

7.4.3 Phn tch kt qu ca h thng lp rp t ng v lp rp lai

Cc kt qu c bn c th c tm tt trong bo co sau y: i vi cc h thng lp rp t ng, lp rp chi ph n v ch yu l xc nh bi cc chi ph c nh. i vi cc h thng lai, lp rp chi ph n v ch yu l xc nh bi cc chi ph bin i. h thng lai phn bit thng qua s thn thin vi vic lm ca h mc d mc cao hp l. Vic lp rp chi ph n v ca cng ngh lp rp lai l cnh tranh trong so snh vi cc gii php t ng cho ton b phm vi qu trnh sn xut. Cc h thng lp rp lai t c cc chi ph mc tiu n v lp rp ngay c vi mt t l sn xut tng i nh. Thc hin cc h thng lai i hi mt chi ph vn tng i thp. Kt hp vi kh nng m rng h thng trong cc giai on, nguy c ca mt khon u t xu l gim.

 Mc thp ca t ng ha trong cc h thng lai tng kh nng ti s dng m-un trong mt h thng mi, sau khi kt thc vng i ca mt sn phm. Kh nng thay i i vi t l u ra ca t ng cng nh lp rp lai c th t c bng cch hoc l tng dn mc t ng ha v / hoc thm hoc loi b cc m-un. S khc bit gia cc ty chn ny nm trong s tin vn u t. ng nhin, cng ngh lp rp lai cng c nhng hn ch ca n. Cn c xem xt mc d khi a ra quyt nh: chc chn ca tin lng bn hng trong mi quan h n i sng sn phm, s lng bin th, kch thc l hng, s lng sn xut hng nm, chin lc bn bn hng. Lp rp t ng hiu qu hn khi t l sn xut sn lng cao vi thi gian chu k t hn ba giy l cn thit v doanh s bn hng nht nh. Khi c quyt nh l khng r rng, l khuyn co rng c hai gii php c th c nh gi v so snh.

7.5 Kt lun
H thng lp rp d dng hn thit k cho kh nng hay thay i cao so vi cc h thng sn xut cho cc b phn c kh. Ni chung, chng c b tr m-un khng ch lin quan n cc qu trnh m cn cc chc nng chuyn giao v b m, cng nh h thng kim sot. Cc bin th sn phm c th c x l bng cch chn g mt phn linh hot vo cc khay v gi . Cc s thay i khi lng thng c a v chm sc bi kh nng thay th cc hot ng bng tay ca cc mun t ng v / hoc nhn i cc trm. Xu hng chung l lm cho nhiu thnh phn ca h thng c th c lp vi hnh dng c th ca cc b phn x l. M hnh kinh doanh trong tng lai nhm mc ch cho vic s dng cc khi nim cho thu cc m-un gim vn u t gn lin vi ti sn c nh.

References
Al-Kashroum O., 1998 Einfluss des Arbeitsablaufs bei der Montage (The Impact of Work Flow in Assemblies). Dissertation TU Chemnitz Kinkel S., (ed)2004, Erfolgsfaktor Standortplanung (Success Factors for Location Planning). Springer Verlag, Berlin/Heidelberg Lotter B. et al., 2006, Primr-Sekundr-Analyse (Primary Secondary Analysis). Expert-Verlag Remmingen 2002 Lotter, B; Wiendahl H.-P. (eds.) Montage in der industriellen Produktion. Ein Handbuch fr die Praxis (Assembly in Industrial Production A Practical Handbook). Springer Verlag Berlin/Heidelberg Lotter E., 2006, Hybride Montagesysteme (Hybrid Assembly Systems). In: Lotter B., Wiendahl H.-P. (eds) Montage in der industriellen Produktion Ein Handbuch fr die Praxis. Springer Verlag, Berlin/Heidelberg, Assembly in Industrial Production A Practical Handbook Rosskopf M., Reinisch H., 2004, Prozessmodulare Gestaltung von Produktionssystemen (Design of Modular Process Production Systems). In: Wiendahl H.-P., Gerst D., Keunecke L. (eds) Variantenbeherrschung in der Montage Konzept und Praxis der flexiblen Produktionsendstufe (Mastering Variants in Assembly Concept and Practices of the Flexible Production Final Segment). Springer Verlag, Berlin/Heidelberg, pp 231260