Why You Need MES On The Assembly Process

An assembly line is a manufacturing process in which interchangeable parts are added to a product in a sequential manner to create an end product. In most cases, a manufacturing assembly line is a semi-automated system through which a product moves. At each station along the line some part of the production process takes place. The workers and machinery used to produce the item are stationary along the line and the product moves through the cycle, from start to finish.

Today, using modern assembly line methods, manufacturing has become a highly refined process in which value is added to parts along the line. Increasingly, assembly line manufacturing is characterized by "concurrent processes"—multiple parallel activities that feed into a final assembly stage.

Here are some examples of different assembly models:

1. Modular Assembly

This is an advanced assembly line method that is designed to improve throughput by increasing the efficiency of parallel subassembly lines feeding into the final assembly line. As applied to automobile manufacturing, modular assembly would involve assembling separate modules—chassis, interior, body—on their own assembly lines, then joining them together on a final assembly line.

2. Cell Manufacturing

This production method has evolved out of increased ability of machines to perform multiple tasks. Cell operators can handle three or four tasks, and robots are used for such operations as materials handling and welding. Cells of machines can be run by one operator or a multi-person work cell. In these machine cells it is possible to link older machines with newer ones, thus reducing the amount of investment required for new machinery.

3. Team Production

Team-oriented production is another development in assembly line methods. Where workers used to work at one- or two-person work stations and perform repetitive tasks, now teams of workers can follow a job down the assembly line through its final quality checks. The team production approach has been hailed by supporters as one that creates greater worker involvement in the manufacturing process and knowledge of the system.

4. U-shaped assembly "line"

A line may not be the most efficient shape in which to organize an assembly line. On a U-shaped line, or curve, workers are collected on the inside of the curve and communication is easier than along the length of a straight line. Assemblers can see each process; what is coming and how fast; and one person can perform multiple operations. Also, workstations along the "line" are able to produce multiple product designs simultaneously, making the facility as a whole more flexible. Changeovers are easier in a U-shaped line as well and, with better communication between workers, cross-training is also simplified. The benefits of the U-shaped line have served to increase their use widely.

Do you see a need for a Manufacturing Execution System?

While looking at these models, can we agree that in each case a proper MES would have to track the components or Kits used, the tools used, the work performed and by whom, showing the proper work instructions, gather machine/ quality parameters, trigger the material replenishment?

Don’t you agree?

Christoph Grauer

Christoph has over 12 years of experience in the IT consulting space in the domain of PLM, ERP and Manufacturing Operations Management. His specialization lies in providing consulting for Manufacturing Operations and PLM solutions. Apart from setting up and leading many implementation projects and global roll outs of business transforming applications in various industries, Mr. Grauer has also taken additional responsibilities of performing Sales and Tech Sales activities. He has successfully setup and executed BOEINGs 2nd Century Enterprise Manufacturing Operations Management program which was the largest Manufacturing Transformation project ever for the French software company Dassault Systèmes.

Andrew Sparrow

I drive Product Innovation & Optimization projects for companies using cutting-edge tech & software solutions to keep them at the forefront of the customer-centric 4IR

I blog, vlog & podcast passionately about our need to innovate & thrive, about managing the product lifecycle (PLM) & ever improving smarter manufacturing (MES/MOM/Digital Manufacturing).