Design and Simulation of an Automated System for Assembly of Metal Door Frames

Yeoh, Bing Quan (2022) Design and Simulation of an Automated System for Assembly of Metal Door Frames. Masters thesis, Tunku Abdul Rahman University of Management and Technology.

Text 17 YEOH BING QUAN (MES).pdf Restricted to Registered users only Download (8MB)

Abstract

This research delved into designing an automated assembly system for metal frames. Over years of production, the company has been outsourcing the services of frame assembly to a subcontractor local at which all the processes are done manually. The manual operation causes labour intensive and long processing time. Besides, the expenses of outsourcing have increased in recent years, which causes higher operating expenses. Hence, this research objective is to perform an economic feasibility study to evaluate an automated assembly system for metal frames. This research's second and third objectives are to design and analyse an automated assembly system for the metal door frame. Last objective is to optimize the process planning and layout of metal door frame assembly through flow analysis. The methodologies of this research started with performing an economic feasibility study. This involved the collection of data, including process time and the related process costs. The analysis is performed to identify the bottleneck process. The costs for outsourcing and in-house automated assembly line are computed and compared the payback and cost-saving. The methodologies for designing started with determining the process requirements and establishing the design inputs. Based on the design inputs, conceptual designs and detailed 3D engineering models are generated using Solidworks software. Besides, the machine design was analysed to determine the stress, deflection, fatigue, and safety distribution factor. Subsequently, process flow and process planning are generated and perform flow analysis to optimize the planning of more efficient production space and labour utilization. In the final result, the process time study shows the welding process is the bottleneck process in the assembly line as it takes 53% of the total process time to complete. Hence, the critical process that needs to be automated in priority is the welding process. The computation of cost and analysis results shows that the company generates a cost-saving of approximately 40% compared to the current outsourcing method, and the payback is within one year. In addition, three automated assembly systems have been designed individually and integrated into a complete assembly line, except for loading and unloading processes. The assembly sequences are merging, pressing, welding, and grinding with a flipping mechanism that allows the two faces of the frame to be welded and ground. Types of sensors are used in the machine for OEE monitoring purposes. The stress applied on the machine did not exceed the yield strength of the material. The defined average factor of safety distribution is 3, which is within the general recommendation of 5 for application usage. Last but not least, process flow and process planning have generated two options for the assembly line. The first option is automated welding only and the second option is automated merging, pressing, welding, and grinding. Under planning, both options use 5 operators to perform the processes and both options require 9.14 hours of working hour per day in order to achieve 15,000 units of door frame per month. In order to enable the optimal planning of a more efficient and utilisation of labour, flow analysis of the options is performed. The result shows the process planning and layout planning of the first option is optimal where the second option can further reduce an operator without affecting the performance of production. The result also shows the first option is more advisable to select in order to make profit of the company. This project contributed to cost efficiency and better profitability for the company. The automated system of production serves to align the company to drive their Industry 4.0 initiative too.