Why did you develop modular assembly as a supplementary manufacturing idea?
Wolfgang Kern: Whenever now we have appreciable variability and a sure dynamic, the inflexible assembly line system reaches its limits or requires additional effort. We should be capable of symbolize that exterior complexity in our inner procedures. Modular assembly directs itself and can actively reply to the rising want for flexibility. As it stands, by linking the belt with the cycle, we at all times have interdependencies. When we alter one thing at one station, it impacts different areas alongside the line. By de-linking them by way of modular assembly, we will make adjustments a lot more simply and exactly. We can even combine new product variants more shortly.
Josef Weinzierl: Modular assembly shouldn’t be an finish in itself and it’s not the one superior system. But it does develop our toolbox for responding to future challenges in car assembly. The assembly line will nonetheless exist in the future, however it should more and more attain its limits, notably in pre-assembly. That’s why we want more complicated options to the ensuing challenges. It’s a matter of augmenting an overarching assembly system. This permits for a bigger diploma of flexibility which is one among the predominant objectives of our new manufacturing technique.
What’s new on this assembly and logistics idea?
Josef Weinzierl: Modular assembly shouldn’t be a bodily assembly line; it is a digital one. Products can take varied routes by way of it throughout manufacturing.
What are the challenges modular assembly faces in sequence manufacturing?
Wolfgang Kern: This new approach of organizing has giant potential, however it additionally means we should rethink the processes we’ve established over a number of years. On prime of that, it requires the proper management software program. It has to satisfy stability standards and industrial feasibility over the long run. We should additionally switch right this moment’s inner working procedures and guidelines to the new idea.
How do staff profit from modular assembly?
Wolfgang Kern: Because of the de-coupled stations, manufacturing will be tailored more simply to the particular person employee. That applies to the coaching stage, ongoing operations, and accommodating staff with particular wants. Overall, we’re enhancing standard manufacturing work and making it more flexible. We’re considerably neutralizing right this moment’s assembly line compartmentalization. We can carry out a complete manufacturing step at one station and, in doing so, have an built-in assembly job. We can even individually adapt each the workspace and the goal instances. This approach, we will modify the workspace to a employee’s top. On prime of that, we will prolong the allotted time in line with an worker’s capabilities. Automated guided autos additionally give us ergonomic advantages.
Josef Weinzierl: Modular assembly provides us a superb alternative to individualize the workspace into more of a singular station than it’s right this moment. Segmented assembly does not essentially need to be unfold out amongst a number of employees. This, in flip, reduces the qualification necessities and the want for 2 colleagues to work in parallel in a small set up area and synchronize their work.
Is modular assembly more economical than a strict assembly line?
Wolfgang Kern: It is more economical once we want a solution to the query of excessive variability and dynamics. We can have a complete assembly job at one station. With this idea, we’re additionally optimizing assembly and logistics holistically by integrating logistics into the modular system.
What does the goods-to-person precept imply for modular assembly?
Wolfgang Kern: It’s elementary to it. Wherever now we have a excessive diploma of element variance, standard strategies of offering supplies are now not enough. In the flexible assembly idea, the precise sequence of merchandise shouldn’t be decided a number of days prematurely however with comparatively brief discover. So, we have to automate the logistics course of additional, which additionally presents a lot potential for financial savings.
Are there fashions for modular assembly?
Wolfgang Kern: A latest study by Germany’s National Academy of Science and Engineering (acatech) discovered that many firms in varied industries are actually wanting into this subject. It identifies our pilot venture for instance of greatest practices and a bellwether in automotive manufacturing.
What comes after the profitable pilots in door pre-assembly?
Josef Weinzierl: We’re concerned in making the idea prepared for mass manufacturing, which suggests making use of working numbers from sequence manufacturing as the customary. Our pilot venture is proving that modular assembly meets the necessities of stability, suitability for our employees, and availability for sequence manufacturing. At the identical time, we’re upcoming new car initiatives to seek out utility areas the place we will viably implement our system. We should rigorously suppose by way of that step into sequence manufacturing as a result of there’s no going again at that time.
When will you get there?
Josef Weinzierl: We will be in serial manufacturing for pre-assembly on a brand new car venture beginning in 2025.
