Flexibility, agility, and cost efficiency remain the drivers of this sector. Assembly can be labor intensive, automated, or both. The same plant sometimes houses a lights-out line and a manual operation under one roof.
The major concerns facing providers of assembly technology "are strikingly similar to those from 10, 15, and even 100 years ago," says Kevin Gingerich, director of marketing services at Bosch Rexroth Corp's Linear Motion and Assembly Technologies. "How can we help users of our equipment optimize their assembly operations?" Today, though, "one of the key challenges is helping manufacturers sort through the huge array of assembly equipment options and techniques to make sure they're getting the productivity enhancements they need." (For more, click here.)
Another challenge "is to increase efficiencies and reduce costs in end-user assembly operations, especially those involving mature technologies and labor-intensive processes," according to John Earley, marketing manager, Fastener Div/Avery Dennison's Retail Information Services Div. (For more, click here.) (Photo shows Extra Heavy Duty T-End.)
Lanco Assembly Systems president Tom Zack believes that the sector "will need to find solutions that can be manufactured in 12-16 weeks, rather than 6-9 months," in manual and automated environments. (For more, click here.)
"Developing more compact inspection components to integrate within assembly machines is important for machine builders," states Jason Mulliner, vision product manager at National Instruments. "As assembly machines become more complex, the ability to visually provide feedback and make inspection measurements immediately rather than at final test is crucial." (For more, click here.)
Fastener suppliers are meeting demands for flexibility with "multi-duty fastening devices; new manufacturing methods (and diverse materials) to reduce the costs of hardware components; automated assembly tools and 'smart' software for error-free, fast, dependable hardware handling and installation," adds Leon M. Attarian, director of corporate marketing at PennEngineering. (For more, click here.) (Photo: PEMSERTER fastener-installation press complete with compatible robotics and "smart" software.)
The industry also must contend with "health related issues and worker safety in manual assembly related operations," believes Jon Fortuna, product manager at Monarch Hydraulics' Dyna-Lift Div. Misaligned working surfaces and "parts that are positioned slightly beyond the reach of employees" can hurt productivity and pose serious safety issues. "Companies are willing to pay for ergonomically designed workstations and lifting devices as a way to combat this problem" because of quick paybacks, Fortuna says. (For more, click here.)
And Schleuniger crimping product manager Rob Boyd notes that with the US moving toward "low-volume or very technical manufacturing . . . machine change-over times will become more important and machines will need to be made simpler to operate. Machines need to be designed so that almost anyone can walk up to them and operate the machine with minimal training." (For more, click here.)
What Innovations Are In Store?
"For automation components, we are seeing more in terms of position feedback actuators and custom designed solutions to specifically address the unique attributes of each project," says Dennis Stuerzenberger, director of business development at PHD Inc.(For more, click here.)
Notes Balluff Inc assembly applications manager Tom Rosenberg: "Advances in optical and laser sensor technologies are increasing assembly equipment precision and reliability by delivering critical position feedback on small parts, while improving setup ease and worker safety." (For more, click here.) (Pictured, self-contained through-beam sensors do not require alignment between beam sender and receiver.)
The assembly sector will increasingly turn to "adhesives, sealants, potting compounds and coatings over conventional mechanical fasteners and assembly devices," believes Dr. Walter Brenner, manager of R & D at Master Bond Inc. "Specific advantages of these newer technologies include lighter weight, virtual elimination of corrosion problems, reduced manufacturing steps, higher productivity and the use of a semiskilled work force." (For more, click here.)
"Integration of IT technology into the individual workstation is accelerating," according to Ray Gottsleben, general manager at Lista International's Arlink Workstation Systems. "With the advent of relatively low cost and space efficient flat panel monitors, customers are increasing their push toward paperless work instructions. Low cost wireless networking is also contributing as the task of 'wiring' a production line to the network becomes simpler and the reduction in 'hard' wiring makes it more practical to change the entire layout of a production facility without having to deal with complex rewiring issues." (For more, click here.)
Liability issues and labor cost pressures increase the importance of ergonomics, Aimco director of training & marketing Steve Bulleit tells IEN. "Engineers need to reduce or eliminate torque reaction, provide lighter tooling or support structures, and reduce noise and vibration of the tooling. Assembly tools suppliers are responding by bringing innovative tooling to the marketplace, especially with the latest generations of pulse tools." (For more, click here.)
Topper Industrial president Ed Brown notes that "mobile workstation carts eliminate both worker fatigue and forklifts from the factory floor. These carts have come out in a variety of designs to match the types of loads brought to the line and the function at that point of the process." (For more, click here.)
"Perhaps the most recent technological advance has been the development of formed-in-place gasket materials that can replace both precuts and silicones for many applications," says Andrew Bachmann, Dymax president and CTO. (For more, click here.)
Phil Heil, IT director at DVT, tells IEN he expects continued "advances in interoperability between devices. Ethernet has proven to be an effective medium to tie many technologies together. The companies who embrace this transport and open their systems will enjoy increased sales from OEM and machine builders. People are less likely to write or buy custom drivers when open protocols abound such as Modbus and Ethernet/IP." (For more, click here.)
Gingerich points to the "continuing computerization of the factory -- whether in the form of PC-based control systems that supplant higher order PLCs or mainframes, or in the form of Internet-enabled workstations in lean-manufacturing cells."
Where Are the R & D Hot Spots?
Zack emphasizes "the new wave in low-cost robots" and the use of servo systems, and believes that "lower-cost vision systems will impact mistake-proofing techniques being used." Gingerich's list includes "faster conveyors, more intelligent parts routing, lean manufacturing, high-speed robotics."
Machine vision vendors are implementing CMOS technology. "Many of the mass produced consumer digital cameras employ CMOS chips," Heil explains. He sees a "cost benefit that allows price breaks in the machine vision market. R & D is focused on making these devices stand up to the rigors of an industrial setting," he adds.
"As assembly operations are pushed to become more flexible and responsive to changing market conditions, wireless will become a necessity in planning flexible manufacturing cells," according to Bill Arnold, marketing manager/semiconductor industry at Omron Electronics LLC. "Wireless provides the ability to move individual pieces of equipment around without having to rewire extensive data cables or I/O cabling to a supervisory controller," he continues. (For more, click here.)
Gingerich notes that "it's already possible to program a robot thousands of miles away using Internet technology, perform remote troubleshooting and show real-time simulations." Size of enterprise can determine the web's usefulness, Boyd believes. "It largely depends on the company and the market they serve. For companies that have multiple facilities, the Internet and intranets have been key in keeping control of materials and production schedules. This is especially true for a U.S. company with their manufacturing in China where the time difference is up to 12 hours."
Throughput can be matched to customer demand, to a point. Banner Engineering's Dave Fletcher observes: "We seem to think that this is achievable with manufacturing and the usage of technology. In some aspects this can be met. In other aspects it cannot be done cost effectively and probably should not be strived for as a goal. We need to clearly understand the process to know what JIT really means and needs to provide to every phase of an operation." (For more, click here.)
Stuerzenberger suggests implementing "small flexible assembly cells that can be replicated many times over as demand ramps up. In a period of slower demand, only the appropriate number of modules is utilized. This flexible assembly process mindset allows many plants to build to demand rather than to forecast," Stuerzenberger tells IEN.
Right sizing remains a major -- and elusive -- goal.
"The first and second tier suppliers have to weigh the real demand requirements against the potential demand (promised work) to decide on the proper production rate to size equipment," states Zack. He urges manufacturers to set "realistic machine expectations" by estimating "how many good parts will be shipped based on reasonable machine efficiencies, operator interactions, etc." According to Gingerich, the "biggest challenge is managing customer demand spikes."
Is Lean Making Inroads?
Since Nordson launched its lean initiative in January 2002, efficiency has jumped. At its Swainsboro, GA, plant for example, "melters are manufactured with 80% less lead time required than the legacy units they replace," reports Ruth Smith, vp of operations. "The biggest part of lean is changing the way we think, changing our culture to incorporate more of a team approach," says Smith. (For more, click here.)
Stuerzenberger sees "more in terms of simple automation that is application specific that gets the job done without needless complication."
Meanwhile, "cellular assembly normally shortens the distance product travels in assembly, provides immediate feedback to upstream processes and facilitates process optimization," according to Stuerzenberger. "The key is flexibility and response to what the process metrics are telling you about your operation. Product specific cells are an excellent method to optimize the assembly process." Still, "common sense has to prevail" in balancing fixed assets with assembly cells.
Experts see some progress toward integrating the front office, the extended enterprise (logistics, etc.) and assembly.
Bachmann points to the new ISO. "With the push to ISO 2000 we are seeing more integration of management, sales and marketing particularly, with prospects and customers," he explains. "The old ISO emphasized product quality. The new standard emphasizes not only product quality, but quality in all of our services that impact customers."
"This is where the real focus seems to be in a 'pull'-type assembly system," Gingerich observes. "Since you're building to order, you need to put extensive focus on the supply chain so that you don't have to carry too much inventory."
