More Efficiency with proper Assembly Planning

Together, we will design your assembly processes

Despite increasing automation possibilities, assembly processes are still among the most labour-intensive work processes in the manufacturing industry. At the same time, the lack of skilled workers has an effect. In our view, however, optimizing the interaction between the two instances is much more important than simply replacing humans. Where can the use of automation technology specifically relieve or even replace people and where is the use of human intelligence still important? These are the central questions of innovative assembly planning.

As experts in discrete manufacturing processes, assembly planning is one of our core competences. Together, we analyze which assembly principles are best suited to your products and design a compatible overall system with an efficient connection to the upstream and downstream process steps.

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Cycle time. Line design. Automation. But how?

Many factors flow into the solution design, such as the selection of the appropriate assembly principle, the cycle time, the design of the material supply or the determination of the appropriate degree of automation.

Furthermore, hybrid assembly systems are becoming an increasingly important aspect of human-machine collaboration. Practical observations repeatedly show that highly automated systems do not achieve the intended performance level because the interaction with humans is not harmonized. As a result, value creation potential remains unutilized, which can quickly become business-critical in the competition for an attractive price level.

High-tech assembly line with robotic arms automating the production of solar panels in a modern manufacturing facility.

Designing a future-orientated assembly system

With many years of experience in discrete manufacturing, we will support you in designing your assembly system to meet your requirements. Following a detailed process analysis, the introduction of (collaborative) robotics or the integration of IoT technologies are possible next steps. In close coordination with all parties involved, we ensure that the integration of automated or hybrid systems is also successful for your company.

Customization of your assembly system

The customization factor plays a major role in the planning of the assembly system, as the target output per unit of time, for example, is the decisive factor. If you are already clear about the appropriate assembly principles in your factory, we will support you with the specific design. Otherwise, we will work together to determine the optimum principle, taking into account your product characteristics, the variance and the expected quantity development. In the area of conflict between flexibility and efficiency, the principle to be favored can range from site-built assembly to sequenced flow line to matrix principle.

How do we bring assembly planning and production logistics together?

In planning projects, it is becoming increasingly apparent how important it is to consider the interface to production logistics directly for assembly planning. Determining the decoupling points and buffer ranges is essential in order to enable a demand-based material supply to the assembly (lines) in production operations. As a result, the necessary picking areas or supermarkets are dimensioned in the layout, for example.

The basic concept is followed by the selection of suitable load carriers and compatible conveyors for the provision of the required components and c parts. However, the interface to production logistics does not end with the assembly supply, but also includes the subsequent material flow towards the end product.

High-tech factory floor with advanced automated assembly lines and optimized production logistics for efficient material flow management.

Mixed-model assembly for greater variant flexibility

In discrete manufacturing, the number of variants is constantly increasing. With mixed-model assembly, different product variants can be assembled on a common line, provided the prerequisites are met. This requires careful planning of cycle times, targeted production planning and control and a reliable supply of materials from production logistics. The result is a line that can react flexibly to a changing product mix without additional buffers and extensive retooling.

Including economic factors

In order to identify the optimum solution for the design of the production logistics surrounding the assembly system, economic factors are also important in addition to functional aspects. For example, FTE calculations or the determination of amortization periods for different equipment variants have a significant influence on the final decision.

Automation and system integration
Simulation for more reliable desicion-making

The more standardized your assembly process is, the more important it is to consider automation and system integration. Given the complexity of these processes, static considerations during the planning stage are often no longer sufficient to provide a sound basis for decision-making. In these cases, selected simulation methods and tools help to anticipate the behaviour in the system network or particularly complex sub-areas.

FAQs about Assembly Planning

How can hybrid assembly systems be successfully integrated into existing production structures?

Hybrid assembly systems that collaboratively link man and machine place high demands on planning and implementation. Successful integration requires a structured analysis of the process steps in which automatable and non-automatable activities are precisely coordinated. Particularly critical here is the cycle compatibility between man and machine, the integration into the production logistics system for successful material supply and disposal and the ergonomics at the transfer points between automated and manual activities.

What criteria determine the optimum assembly principle for my product portfolio?

The selection of a suitable assembly principle is not a standard process, but results from the combination of product-specific characteristics (e.g. variety of variants, volume, complexity), desired scalability and the economic target values. Construction site assembly, flow assembly or the matrix principle each have their own strengths - for example in dealing with fluctuating quantities. Based on a systematic analysis of your product structure and process requirements, Metroplan develops an individual evaluation scheme that leads to the selection of the principle with the best suitability.

How can the interface between assembly planning and production logistics be optimized?

A lack of synchronization between assembly and logistics planning often leads to material bottlenecks, inefficient buffer structures or unnecessary handling costs. It is therefore crucial to take an integrated view of both areas - for example, when determining decoupling points, designing supermarkets and picking stations and selecting load carriers and conveyor systems. In complex areas, the system behavior can be specifically analyzed through the targeted use of simulations in order to identify any challenges at an early stage.