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Article
Publication date: 25 October 2021

Anil Kumar Gulivindala, M.V.A. Raju Bahubalendruni, Anil Kumar Inkulu, S.S. Vara Prasad Varupala and SankaranarayanaSamy K.

The purpose of this paper is to perform a comparative assessment on working of the existed subassembly identification (SI) methods, which are widely practiced during the product…

172

Abstract

Purpose

The purpose of this paper is to perform a comparative assessment on working of the existed subassembly identification (SI) methods, which are widely practiced during the product development stage and to propose an improved method for solving the SI problem in assembly sequence planning (ASP).

Design/methodology/approach

The cut-set method is found as a suitable method among various knowledge-based methods such as the theory of loops, theory of connectors and theory of clusters for the workability enhancement to meet the current requirements. Necessary product information is represented in the matrix format by replacing the traditional AND/OR graphs and the advanced predicates are included in the evaluation criteria.

Findings

The prominent methods in SI are followed a few of the predicates to avoid complexity in solution generation. The predicate consideration is found as the most influencing factor in eliminating the infeasible part combinations at SI. However, the quality of identified subassemblies without advanced predicates is not influencing the solution generation phase but practical applicability is affecting adversely.

Originality/value

The capability of performing SI by the cut-set method is improved to deal with the complex assembly configurations. The improved method is tested by applying on different assembly configurations and the effectiveness is compared with other existent methods of ASP along with the conventional method.

Details

Assembly Automation, vol. 41 no. 6
Type: Research Article
ISSN: 0144-5154

Keywords

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Article
Publication date: 26 August 2020

Anil Kumar Gulivindala, M.V.A. Raju Bahubalendruni, S.S. Vara Prasad Varupala and Sankaranarayanasamy K.

Parallel assembly sequence planning (PASP) reduces the overall assembly effort and time at the product development stage. Methodological difficulties at framework development and…

261

Abstract

Purpose

Parallel assembly sequence planning (PASP) reduces the overall assembly effort and time at the product development stage. Methodological difficulties at framework development and computational issues at their implementation made the PASP complex to achieve. This paper aims to propose a novel stability concept for subassembly detection to minimize the complexities in PASP.

Design/methodology/approach

In this research, a heuristic method is developed to identify, represent and implement the stability predicate to perform subassembly detection and assembly sequence planning (ASP) at the further stages. Stability is organized into static, dynamic, enriched and no stability between the mating assembly parts. The combination of parts that possesses higher fitness is promoted to formulate the final solution about PASP.

Findings

The results obtained by applying the proposed concept on complex configurations revealed that stability predicate plays a dominant role in valid subassembly detection and final sequence generation further.

Originality/value

The value of the presented study lies in the three types of stability conditions and effective integration to existed ASP method. Unlike the existed heuristics in subassembly detection, the proposed concept identifies the parallel subassemblies during ASP.

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Article
Publication date: 26 March 2019

M.V.A. Raju Bahubalendruni, Anil Gulivindala, Manish Kumar, Bibhuti Bhusan Biswal and Lakshumu Naidu Annepu

The purpose of this paper is to develop an efficient hybrid method that can collectively address assembly sequence generation (ASG) and exploded view generation (EVG) problem…

210

Abstract

Purpose

The purpose of this paper is to develop an efficient hybrid method that can collectively address assembly sequence generation (ASG) and exploded view generation (EVG) problem effectively. ASG is an act of finding feasible collision free movement of components of a mechanical product in accordance with the assembly design. Although the execution of ASG is complex and time-consuming in calculation, it is highly essential for efficient manufacturing process. Because of numerous limitations of the ASG algorithms, a definite method is still unavailable in the computer-aided design (CAD) software, and therefore the explosion of the product is not found to be in accordance with any feasible disassembly sequence (disassembly sequence is reverse progression of assembly sequence). The existing EVG algorithms in the CAD software result in visualization of the entire constituent parts of the product over single screen without taking into consideration the feasible order of assembly operations; thus, it becomes necessary to formulate an algorithm which effectively solves ASG and EVG problem in conjugation. This requirement has also been documented as standard in the “General Information Concerning Patents: 1.84 Standards for drawings” in the United States Patent and Trademark office (2005) which states that the exploded view created for any product should show the relationship or order of assembly of various parts that are permissible.

Design/methodology/approach

In this paper, a unique ASG method has been proposed and is further extended for EVG. The ASG follows a deterministic approach to avoid redundant data collection and calculation. The proposed method is effectively applied on products which require such feasible paths of disassembly other than canonical directions.

Findings

The method is capable of organizing the assembly operations as linear or parallel progression of assembly such that the assembly task is completed in minimum number of stages. This result is further taken for EVG and is found to be proven effective.

Originality/value

Assembly sequence planning (ASP) is performed most of the times considering the geometric feasibility along canonical axes without considering parallel possibility of assembly operations. In this paper, the proposed method is robust to address this issue. Exploded view generation considering feasible ASP is also one of the novel approaches illustrated in this paper.

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Article
Publication date: 25 January 2024

Anil Kumar Inkulu and M.V.A. Raju Bahubalendruni

In the current era of Industry 4.0, the manufacturing industries are striving toward mass production with mass customization by considering human–robot collaboration. This study…

225

Abstract

Purpose

In the current era of Industry 4.0, the manufacturing industries are striving toward mass production with mass customization by considering human–robot collaboration. This study aims to propose the reconfiguration of assembly systems by incorporating multiple humans with robots using a human–robot task allocation (HRTA) to enhance productivity.

Design/methodology/approach

A human–robot task scheduling approach has been developed by considering task suitability, resource availability and resource selection through multicriteria optimization using the Linear Regression with Optimal Point and Minimum Distance Calculation algorithm. Using line-balancing techniques, the approach estimates the optimum number of resources required for assembly tasks operating by minimum idle time.

Findings

The task allocation schedule for a case study involving a punching press was solved using human–robot collaboration, and the approach incorporated the optimum number of appropriate resources to handle different types of proportion of resources.

Originality/value

This proposed work integrates the task allocation by human–robot collaboration and decrease the idle time of resource by integrating optimum number of resources.

Details

Robotic Intelligence and Automation, vol. 44 no. 1
Type: Research Article
ISSN: 2754-6969

Keywords

Available. Open Access. Open Access
Article
Publication date: 8 August 2023

Elisa Verna, Gianfranco Genta and Maurizio Galetto

The purpose of this paper is to investigate and quantify the impact of product complexity, including architectural complexity, on operator learning, productivity and quality…

858

Abstract

Purpose

The purpose of this paper is to investigate and quantify the impact of product complexity, including architectural complexity, on operator learning, productivity and quality performance in both assembly and disassembly operations. This topic has not been extensively investigated in previous research.

Design/methodology/approach

An extensive experimental campaign involving 84 operators was conducted to repeatedly assemble and disassemble six different products of varying complexity to construct productivity and quality learning curves. Data from the experiment were analysed using statistical methods.

Findings

The human learning factor of productivity increases superlinearly with the increasing architectural complexity of products, i.e. from centralised to distributed architectures, both in assembly and disassembly, regardless of the level of overall product complexity. On the other hand, the human learning factor of quality performance decreases superlinearly as the architectural complexity of products increases. The intrinsic characteristics of product architecture are the reasons for this difference in learning factor.

Practical implications

The results of the study suggest that considering product complexity, particularly architectural complexity, in the design and planning of manufacturing processes can optimise operator learning, productivity and quality performance, and inform decisions about improving manufacturing operations.

Originality/value

While previous research has focussed on the effects of complexity on process time and defect generation, this study is amongst the first to investigate and quantify the effects of product complexity, including architectural complexity, on operator learning using an extensive experimental campaign.

Details

Journal of Manufacturing Technology Management, vol. 34 no. 9
Type: Research Article
ISSN: 1741-038X

Keywords

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