Final assembly eATV – Halocline Help Desk

This article is based on the sample data of the HaloPlant demo shopfloor. If it is not available to you, you can find the download instructions here: Download sample data

Overview

This HaloPlant work area shows the development of an industrialization project based on the final assembly of a product to be manufactured (here the beach buggy serves as example).

The development steps can be reproduced in separate variants, from the initial considerations for assembly, to the components required for each station, to the finished concept.

In focus

Industrialization

A production concept is created and implemented for a (market-ready) product. The project team involves all relevant parties in the creation of the concept. Their input is one of the key factors in determining the concept contents. The concept may already contain a plan regarding the expansion stages along the ramp-up curve. The industrialization project typically ends when the production start is reached.

Assembly planning - from rough to detailed planning

During rough assembly planning, the main components of the assembly are identified and the required resources such as components, tools, operating resources and personnel are determined. Detailed planning then determines in detail which work steps are to be executed in which order to carry out the assembly as efficiently as possible.

Variants & Workflow

Concept v1 - area divided into stations
Lined up assembly states Determined number of stations Divided area into stations Used boxes with 1 cm height and 5 cm width for the lines
Concept v2 - Assignment of the required components
Assigned components to each station Used document "Assembly sequence" Indicated Assembly sequence in Halocline Layout by spatial arrangement
Concept v3 - placing the components in containers
Decision: Vehicle is mounted on an assembly cart and moved by hand to the next station Placed (small) components in boxes Shows area packaging (brown)
Concept v4 - summary of stations
Combined stations (shock absorber + seat & pedals + e-motor), since the individual workload is very unlikely to fill the full cycle Planned gained space for storage of manufactured eATV (green)
Concept v5 - Detailing the provision of materials
Placed containers in racks Placed work tables for pre-assembly (front axle, rear axle, axle e-motor) Reserved area for staging carts (cladding & inner lining) (blue)
Concept v6 - Tools placed & EoL area planned
Placed large components in wire mesh boxes Created EoL visual inspection Placed tools
Concept v7 - Completion of the concept
Redesigned carts for staging on the line in Halocline Layout Designed Packaging area
Concept v7 - container colored per station
Aims to better understand the parts needed per station Helps to notice planning or thinking errors to be able to fix them at an early stage

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