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New era of automation in Scania’s manufacturing systems

Abdalrahman, Moutoz LU and Brice, Alistair LU (2021) MMTM05 20211
Production and Materials Engineering
Abstract
Today's car and truck industries are perceived as having complex production
systems and relatively high manufacturing expenses, such as labour cost, which is usually combined with complex and unergonomic assembling tasks. A shift towards automation is one solution to eliminate such tasks while increasing productivity and lowering labour costs. Many products and assembly operations are designed to be performed manually, which creates additional challenges to re-shape these operations so that machines can carry them. The future is here, and what used to be manual, repetitive, and inefficient can now be automated. This master’s thesis suggests a potential solution of a fully automated assembly line of a steering wheel and front wheel on a... (More)
Today's car and truck industries are perceived as having complex production
systems and relatively high manufacturing expenses, such as labour cost, which is usually combined with complex and unergonomic assembling tasks. A shift towards automation is one solution to eliminate such tasks while increasing productivity and lowering labour costs. Many products and assembly operations are designed to be performed manually, which creates additional challenges to re-shape these operations so that machines can carry them. The future is here, and what used to be manual, repetitive, and inefficient can now be automated. This master’s thesis suggests a potential solution of a fully automated assembly line of a steering wheel and front wheel on a pedal car; developed, tested, evaluated, and finally implemented in Scania's Smart Factory Lab. The study can be seen as a potential base and a physical demonstrator for implementing such a system in an actual assembly line. It has proven that even manually designed assembly tasks can be automated without a need for redesigning the process or the components involved. The study suggests a method to transform manual assembly operations into automated ones, the method is flexible and can be modified and applied for other types of manual assembly processes. Thereafter, the developing, testing, and implementation of some of the main automation system components, including the physical resources within the production line for the pedal car. Finally, the experienced challenges regarding the automation system components are summarised. (Less)
Abstract (Swedish)
Dagens bil- och lastbilsindustri upplevs ha komplexa produktionssystem med relativt höga tillverkningskostnader, varav en stor del kan kopplas till arbetskostnader vars arbetsmoment utgörs av komplexa och icke ergonomiska monteringsuppgifter. Genom att automatisera sådana uppgifter kan produktiviteten öka samtidigt som arbetskostnader och sjukfrånvaro minskar. Många produkter och monteringsoperationer är utformade för att utföras manuellt, vilket skapar ytterligare utmaningar när det kommer till att omforma dessa till automatiserade lösningar. Men, framtiden är här, och det som brukade vara manuellt, repetitivt och ineffektivt kan nu automatiseras. Denna uppsats föreslår en potentiell lösning för en helautomatiserad monteringslinje för... (More)
Dagens bil- och lastbilsindustri upplevs ha komplexa produktionssystem med relativt höga tillverkningskostnader, varav en stor del kan kopplas till arbetskostnader vars arbetsmoment utgörs av komplexa och icke ergonomiska monteringsuppgifter. Genom att automatisera sådana uppgifter kan produktiviteten öka samtidigt som arbetskostnader och sjukfrånvaro minskar. Många produkter och monteringsoperationer är utformade för att utföras manuellt, vilket skapar ytterligare utmaningar när det kommer till att omforma dessa till automatiserade lösningar. Men, framtiden är här, och det som brukade vara manuellt, repetitivt och ineffektivt kan nu automatiseras. Denna uppsats föreslår en potentiell lösning för en helautomatiserad monteringslinje för ratt och framhjul på en trampbil; utvecklad, testad,utvärderad och implementerad i Scanias Smart Factory Lab.Studien kan ses som en potentiell bas och fysisk demonstrator för att implementera ett sådant system i en verklig monteringslinje. Studien har även visat att produkter som är utformade för manuell montering kan automatiseras utan att behöva anpassa dem för automatisering. Studien föreslår en metod för att omvandla manuell montering till en automatiserad process, metoden är flexibel och kan tillämpas vid andra typer av manuella monteringsprocesser. Därefter följer en beskrivning av design, test och implementering på några av de viktigaste automatiseringsystemkomponenterna, inklusive de fysiska resurserna i produktionslinjen för trampbilen. Slutligen kommer en sammanfattning av de upplevda utmaningarna gällande systemets automation komponenter. (Less)
Please use this url to cite or link to this publication:
author
Abdalrahman, Moutoz LU and Brice, Alistair LU
supervisor
organization
alternative title
A method to automate a manual assembly process
course
MMTM05 20211
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Assembly, Industry 4.0, Industrial Automation, Robot, Production, Automotive.
report number
LUTMDN/(TMMV-5321)/1-107/2021
language
English
id
9053201
date added to LUP
2021-06-13 14:38:17
date last changed
2021-06-13 14:38:17
@misc{9053201,
  abstract     = {{Today's car and truck industries are perceived as having complex production 
systems and relatively high manufacturing expenses, such as labour cost, which is usually combined with complex and unergonomic assembling tasks. A shift towards automation is one solution to eliminate such tasks while increasing productivity and lowering labour costs. Many products and assembly operations are designed to be performed manually, which creates additional challenges to re-shape these operations so that machines can carry them. The future is here, and what used to be manual, repetitive, and inefficient can now be automated. This master’s thesis suggests a potential solution of a fully automated assembly line of a steering wheel and front wheel on a pedal car; developed, tested, evaluated, and finally implemented in Scania's Smart Factory Lab. The study can be seen as a potential base and a physical demonstrator for implementing such a system in an actual assembly line. It has proven that even manually designed assembly tasks can be automated without a need for redesigning the process or the components involved. The study suggests a method to transform manual assembly operations into automated ones, the method is flexible and can be modified and applied for other types of manual assembly processes. Thereafter, the developing, testing, and implementation of some of the main automation system components, including the physical resources within the production line for the pedal car. Finally, the experienced challenges regarding the automation system components are summarised.}},
  author       = {{Abdalrahman, Moutoz and Brice, Alistair}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{New era of automation in Scania’s manufacturing systems}},
  year         = {{2021}},
}