1. Automated Assembly Facility Design Tinisha McMillion ET-494 Spring 2014 Advisor: Dr. Roy Bonnette Instructor: Dr. Cris Koutsougeras

2. OVERVIEW  Design an Automated Assembly for DELL model M-UVDEL1 Mouse.  Process Design.  Line Processes.  Automation and Transportation Systems.  Automated Systems Layout.  3-D Modeling of Select Components.  Facility Design and Layout.  Production.

3. SPECIFICS  Process Design.  Disassemble Mouse.  Record placement and order of assembly.  Multiple variations considered.  High level process created.  3 lines – main board, bottom cover, top cover.

4. High Level Process

5.  Individual Line Processes.  Components for each line determined.  Permanent Attachment Method Determined.  Snapping together.  Screw attachment.  Soldering.  Time trials completed.  18 second maximum.  23 second advancement speed determined.

6. Board Assembly Line

7. Bottom Cover Assembly Line

8. Top Cover Assembly Line and Final Assembly Process

9. Time Trials ActionTrial Number AVG SECONDS 12345678910 Solder Memory Chip18 Solder Selection Switches6 Solder LED Light2 Solder USB Base5 Solder Scroll Wheel Switch2 Solder Scroll Wheel Sensing Assembly3 Snap Optic Plate In Place32111111111.3 Position Board33234432243 Attach Board With Screws710857 76.5 67.3 Plug USB Cord Into Base6896765.555 6.3 Scroll Wheel And Springs Assembled And Placed12141512111013 121412.6 Position Weight23422222222.3 Attach Weight With Screw12224334543 Right And Left Selection Buttons Positioned And Attached46544444444.3 Snap Top And Bottom Covers Together1012131112131011 1011.3 Top And Bottom Cover Attached With Screw36545454634.5

10. Equipment  Transportation.  Dorner precision move 2200 series conveyor system.  Machine integration.  Timed conveying.  Accurate part positioning.  Robotic pick and place.  Belt 6” wide, cleat height 1.5”

11. Robotics  UNIX 700-H  Soldering processes.  48.5 pounds.  Floor mounted.  3’ x 5’ operating area.  5 programmable axes.  36 units required.

12.  FANUC M1-iA-1H  Pick & place and screw attachment.  26.5 pounds.  Floor mounted.  2’ x 4’ operating area.  3 programmable axes.  96 units required.

13. 3-D Modeling  Board and cradle.  1/8” gap included for soldering joints.  Bottom cover and cradle.  Rubber inlay created for stability.

14. Board and Cradle

15. Board

16. Cradle for Board

17. Bottom Cover and Cradle

18. Bottom Cover

19. Cradle for Bottom Cover

20. Automated Systems Layout  Robotics size and space requirements.  Flow of materials.  Personnel movement.  5’ allowed for preventative maintenance.  2’ x 2’ Return bins.  2’ x 3’ Material bins.  4’ x 4’ Inspection stations.  6’ x 6’ Manual assembly stations.

21. Complete Assembly Line

22. Facility Design  6 complete assembly lines.  Office space at 150’x91’.  Break rooms at 30’x50’ and rest rooms at 10’x20’.  Maintenance room at 30’x50’.  Shipping and receiving storage at 50’x100’.  Shipping and receiving area at 110’x60’.  Employee/visitor parking  60 – 9’x20’ standard spots for medium sized cars.  6 – 12’x20’ handicapped spaces with additional 5’x20’ area.  Standard 26’ spacing around rows.  Overnight truck parking.  Roads offset 50’, 25’ standard set back.

23. Facility Layout

24. 6 Complete Lines

25. Office Space

26. Rest Rooms and 2 nd Break Room

27. Maintenance Room

28. Shipping and Receiving Areas

29. Employee & Visitor Parking

30. Receiving Flow

31. Shipping Flow

32. Production Rates  Production Goal of 500,000 per year  1 unit per minute.  Material handling, packaging, inventory control, storage, shipping & receiving.  90% efficiency, 2% failure rate* and 3 hours a week for PM on 5 lines.  489,500 units per year which was insufficient.  80% efficiency, 2% failure rate* and 3 hours a week for PM on 6 lines.  522,000 unit per year.  Robotics and facility are not maxed out allowing for future expansion.  *Failure rate attributed to irregular parts, non-functional parts, assembly damage and inspection failures.

33. RESOURCES & REFERENCES  Dr. Roy Bonnette  Jonathan Newsom  James Stutts  Dorner Mfg. Corp.  FANUC  JAPAN UNIX

34. Questions?