Kaj Helin

Total cost of ownership analysis for modular final assembly systems

The objective of modern assembly processes is to produce high-quality and low-cost products. Understanding manufacturing costs in the system design phase is the first step to increasing profits. Throughput, utilization, and cycle time continue to be emphasized as key performance indicators for the planning of new assembly systems, but the cost issues need to be analysed as well. The authors are developing a novel analysis methodology that integrates component-based simulation, Overall Equipment Efficiency with Cost of Ownership, and other analysis methods to improve the design of flexible, modular reconfigurable assembly systems. The development of the Total Cost of Ownership (TCO) analysis tool is based on selected industrial standards and the authors’ own experience of assembly system design and simulation. The TCO method is useful in system-supplier and end-user communication, and helps in trade-off analyses of system concepts. A fictitious case study illustrates the use of the TCO method.

Selecting the right system ‐ assembly system comparison with total cost of ownership methodology

Purpose – To present theories for total cost of ownership (TCO) methodology in assembly system trade‐off analysis and to show benefits of the methodology as a decision support in system selection.Design/methodology/approach – The developed TCO methodology is a combination of factory simulation, system performance and loss factor evaluation using overall equipment efficiency, system life cycle costing, and assembled unit cost analysis including cost of bad quality and rework.Findings – The purchase price of equipment is just one cost element in the comparison. TCO shows how important it is to analyse all the cost, direct and indirect, incurred throughout the life cycle of an equipment, including acquisition and installation, operations and maintenance, and end‐of‐life management. TCO methodology pinpoints costs that could be easily underestimated, such as quality and rework as well as all the costs of running the system.Research limitations/implications – The methodology is partially based on semiconductor...

Digital human model based participatory design method to improve work tasks and workplaces

The objective of this research project was to improve manual work tasks and workplace design with a new digital human model based design method. The idea of the method was to make the design and analyze of work and workplaces easy for floor level development case. It also should to be exploitable in the context of participatory design approach. The developed method was implemented on a production design simulation platform. It was designed to be used in design of human factors, performance and functionality of a production concurrently. The implemented tool includes basic human motions which exploit real human motion data, effective work design features to easily generate variational solutions, embedded ergonomic analyses and checklists to help analyzing different work environment solutions, and to document the design outcome. Four industrial case studies were completed with the tool. The results show that the tool is feasible for individual and group design work, and has positive impacts on the design process and on the way how individuals can influence on her or his future work in production system.

Life Cycle and Cost Analysis for Modular Re-Configurable Final Assembly Systems

This article presents a case study in the design of a modular semi-automated reconfigurable assembly system using life cycle cost analysis methodology. To ensure that an assembly system is appropriately designed, system measurement schemes should be established for determining and understanding design effectiveness. Understanding life cycle costs is the first step toward increasing profits. The authors are developing an analysis tool that integrates Overall Equipment Efficiency (OEE), Cost of Ownership (COO), and other analysis methods to improve the design of flexible, modular reconfigurable assembly systems. The development is based on selected industrial standards and the authors’ own experience in modular assembly system design and simulation. The developed TCO (Total Cost of Ownership) methodology is useful in system supplier and end-user communication and helps in trade-off analysis of the system concepts.

Affordances for Capturing and Re-enacting Expert Performance with Wearables

The WEKIT.one prototype is a platform for immersive procedural training with wearable sensors and Augmented Reality. Focusing on capture and re-enactment of human expertise, this work looks at the unique affordances of suitable hard- and software technologies. The practical challenges of interpreting expertise, using suitable sensors for its capture and specifying the means to describe and display to the novice are of central significance here. We link affordances with hardware devices, discussing their alternatives, including Microsoft Hololens, Thalmic Labs MYO, Alex Posture sensor, MyndPlay EEG headband, and a heart rate sensor. Following the selection of sensors, we describe integration and communication requirements for the prototype. We close with thoughts on the wider possibilities for implementation and next steps.

Advanced manufacturing with augmented reality

During this workshop, the participants will explore themes in three areas: • Augmented Reality and Technical Data Delivery. In this area we will hear from experts and engage in discussion to develop agreement among the workshop participants on what constitutes the state of the art for use of AR to deliver technical data in 2014. • Augmented Reality and the Shop Floor Environment. In this area we will engage in discussion to develop agreement among the workshop participants on what constitutes the state of the art for use of AR to map value streams and increase value, to avoid waste and increase sustainability, and to reduce risk and prevent human error on the shop floor in 2014. This will be documented in a brief, joint statement. Participants will then develop consensus on three major research areas on which there must be further investment in order for the technology to be widely implemented and adopted on the shop floor. • Augmented Reality and Quality Inspection. In this area we will engage in discussion to develop agreement among the workshop participants on what constitutes the state of the art for use of AR to inspect manufactured goods in 2014. This will be documented in a brief, joint statement. Participants will then develop consensus on three major research areas on which there must be further investment in order for the technology to be widely implemented and adopted. The three themes of the workshop are highly relevant to the ISMAR conference, not least since the region — Bavaria — strives in the use of AR in the manufacturing industry. This workshop will increase awareness of the current state of the art in industry and help further develop the research agenda for AR in manufacturing through the identification of common interests and grand challenges. This workshop will produce nine research topics that can become the basis for academic and public/private partnership-funded research projects.

Life Cycle and Unit Cost Analysis for Modular Re-Configurable Flexible Light Assembly Systems

Publisher Summary This chapter illustrates a methodology for the design of a modular semi-automated reconfigurable assembly system using component-based simulation and life cycle cost analysis. To ensure that an assembly system is appropriately designed, system measurement schemes should be established for determining and understanding design effectiveness. Measurements can be classed into two categories: cost and performance. Understanding manufacturing costs is the first step towards increasing profits. The chapter outlines the development of an analysis tool that integrates overall equipment efficiency (OEE), cost of ownership (COO), and other analysis methods to improve the design of flexible, modular reconfigurable assembly systems. The development is based on selected industrial standards and the experience in modular assembly system design and simulation. The developed total cost of ownership (TCO) methodology is useful in system supplier and end-user communication, helps in trade-off analysis of the system concepts, and improves the system specification.

Demonstration: VR-HYPERSPACE — The innovative use of virtual reality to increase comfort by changing the perception of self and space

Our vision is that regardless of future variations in the interior of airplane cabins, we can utilize ever-advancing state-of-the-art virtual and mixed reality technologies with the latest research in neuroscience and psychology to achieve high levels of comfort for passengers. Current surveys on passengers experience during air travel reveal that they are least satisfied with the amount and effectiveness of their personal space, and their ability to work, sleep or rest. Moreover, considering current trends it is likely that the amount of available space is likely to decrease and therefore the passengers physical comfort during a flight is likely to worsen significantly. Therefore, the main challenge is to enable the passengers to maintain a high level of comfort and satisfaction while being placed in a restricted physical space.

PLM Impact Analysis Model – PIA

Our goal was to create a support for better PLM development target identification. A method titled ”PIA – PLM Impact Analysis” was created in order to help recognizing the most value-adding potentials. The method is supported by a MS–Excel based tool. The method was built and developed in workshops interactively with researchers and representatives from companies.

Rock Crusher Upgrade Business from a PLM Perspective

Global trends of ecology and sustainable development, safety awareness, changing legislation, and urbanization, together with the economic situation, force industry to find solutions for extending product lifecycles, while maintaining and improving machine system performance and other properties during the lifecycles. Together with these societal issues, firms are struggling with competitiveness. This chapter introduces the new Use-it-Wisely (UIW) approach to upgrading rock crushers at customer sites. The higher level problem needing to be solved concerned making upgrade delivery projects profitable and more desirable for customers, manufacturing OEMs and suppliers. The main recognized and treated bottlenecks were related to knowing the actual status of the upgrade target, communication and collaboration with stakeholders, verification and validation of upgrade specifications and an efficient information flow between the stakeholders. Augmented reality (AR), Virtual environments (VE), camera based 3D scanning, and cloud based solutions are the selected pieces of technology for solving the bottlenecks. They enable better communication, collaboration and involvement of all stakeholders, including customers, internal stakeholders, suppliers and partners. They also better enable the planning and discussing of service quality activities. Product life-cycle management (PLM) is the framework for developing and managing product related information, processes and collaboration expanding towards product middle-of-life, end-of-life, and service lifecycle management. This study is a proof-of-concept that demonstrates the potential of contributions to business model innovations and game changes for upgrading business.