Development of design improvements to a flexible modular automation product assembly system

Abstract

Manufacturing companies must address changes which take place in the market in order to remain competitive. A local cosmetic packaging firm has introduced a new flexible automation concept to tackle recent market developments. In this project, this new automation concept was analysed. The main aim of the project was to identify the limitations of this concept and suggest design improvements which could be implemented. The DMAIC improvement cycle was selected to accomplish the main aim. Different problem-solving tools were used in the five phases of the cycle. In the first phase, a SIPOC Diagram was used to get a better understanding of the whole flexible concept and also, learn the different manufacturing processes carried out on the production lines. The Sephora Mono compact was selected, and its process was studied in-depth by using a flowchart and a plant layout. In the Measure Phase, three process performance characteristics of the selected line were measured. Several column charts and tables were constructed to display the data collected. The gathered data was analysed thoroughly in the Analyse Phase. Two Pareto Charts were drawn to determine the major causes of downtimes and the most common types of rejects. The Analyse Phase was completed by using a Process Failure Mode and Effects Analysis, where all potential failure modes were listed. Recommended actions were provided for most of the failure modes. In the Improve Phase, the upgrade chosen was to integrate an Automated Pinning Module. A Morphological Chart was used to develop different ideas of how the module could be set up. Two plant layouts were generated, showing two different ideas on how the Pinning Module could be incorporated. The two concepts were rated against six selected criteria. From the Decision Matrix, Concept 2 obtained the highest score, and thus, this idea has the greatest potential to succeed. Finally, another PFMEA was used to recognize and address the risks of the chosen concept.