Assembly Evolution (3/7)

The assembly operation consists of the two basic activities of handling and insertion.  If a product is to be assembled automatically then thought has to be given to the economics of these activities. The automatic feeding of simple parts is usually carried out using a vibratory bowl feeder. Components in bulk random orientation are placed into the feeder and the parts are presented to the workhead in an ordered manner. Difficult parts may be fed by special feeders, hoppers or by magazines. The insertion process is defined as being the action where one part is assembled to another part, or group of parts. High speed operations, where the same parts are inserted for long periods of time, are normally effected by standard pick-and place units. Difficult operations, involving the assembly of a number of different parts with different operations may require assembly robots.  The flexibility of the robot is created by using computer programs to control the robot arm movements. The difference between a robot and a pick-and-place is that the path of the robot arm is not restricted by mechanical means, whereas pick-and-place units rely upon mechanical stops to determine the path they follow.

Division of labour

The division of labour is the process whereby one complex operation is broken down into a number of simpler tasks. These single tasks are carried out using a series of people, each doing one task. In this manner, a complex task performed by one worker is replaced by a number of workers operating in series. This allows operations to be carried out simultaneously, instead of the single operator having to complete one task before commencing another, different task. Unskilled workers can then be used to carry out these simple operations and they soon become efficient at the particular task.

Assembly systems

An assembly method can be classified into one of six types, and most systems may contain a number of different methods.

The traditional form of assembly is manual and, for high volume production, the workers are arranged on an assembly line. Other forms of manual assembly include a single worker assembling a complete product and groups of workers assembling a portion of the product.

When the range of products is more limited, a manual assisted method can be used, whereby workers are assisted by mechanical devices, such as parts feeders. The feeders present the parts to the assemblyworker in an ordered manner.  The assembly time is reduced by eliminating the time taken to separate the parts from bulk random orientation.

The third form of assembly uses automatic indexing assembly machines.  A rotary or in-line machine has a number of workstations with automatic feeders which supply components to workheads for assembly of the part to the fixture, or part-built assembly. The workstations are 'special-purpose' and are dedicated to the assembly of one product only. Production volumes need to be high for the economic justification of these machines. Component quality must also be high to avoid excessive workstation downtime, caused by jamming, etc.