Assembly planning

We’ll help you to increase the flexibility and adaptability of your assembly.

More efficiency and flexibility in assembly 

Adaptability as a key factor

In most companies, the most significant added value in the end product occurs in assembly. Different internal and external flows of goods converge here. Therefore, an intelligent and well-planned assembly is the basis for the successful and sustainable achievement of corporate goals.

However, the increasing number of variants and the simultaneously growing cost pressure make the optimal design of assembly systems a demanding task. In addition to the implementation of cost-efficient assembly processes, the need for flexible and adaptable assembly structures that enable rapid adaptation to volatile influences is growing simultaneously. In a dynamic and complex environment, assembly systems must be designed to meet individual requirements in terms of flexibility and efficiency.    

We have many years of experience in planning and optimizing assembly systems. We will show you how you can use innovative methods to achieve high flexibility with high efficiency and product quality in your assembly system.

Structuring and segmenting the assembly

The basic requirement for an ideal assembly system is structuring and segmenting the assembly following the requirements. To do this, we analyze the assembly processes, product structures and material flows and structure the assembly according to your individual needs. 

For example, we are investigating the potential of subdividing assembly into several pre-assembly areas to reduce complexity and throughput time and increase efficiency through a high degree of specialization of the workplaces.

Based on your specific initial situation, we will work with you to develop a segmentation concept that creates optimal structural conditions for meeting market and customer requirements. We also identify and analyze the interfaces between the individual assembly segments. 

Intending to permanently guarantee the security of supply and keep inventory and space costs low, we will work with you to develop tailor-made buffer and provision strategies for an ideal interlinking of the assembly areas in your production. 

We’ll support you in the assembly planning

  • Assembly structuring and segmentation
  • Selection of assembly concepts that meet the requirements
  • Ergonomic and efficient workplace design
  • Analysis of automation potential & technology planning
  • Resource planning and capacity assessment
  • Use of innovative assembly assistance systems

With assembly segmentation for more transparency and efficiency 

The basic requirement for an ideal assembly system is structuring and segmenting the assembly in accordance with the requirements. For this purpose, we analyze your assembly processes, product structures and material flows and structure the assembly according to your individual requirements. For example, we are investigating the potential of subdividing assembly into several pre-assembly areas to reduce complexity and throughput time and increase efficiency through a high degree of specialization of the workplaces. Based on your specific initial situation, we will develop a segmentation concept that creates the optimal structural prerequisites for meeting market and customer requirements. We also identify and analyze the interfaces between the individual assembly segments. To permanently guarantee security of supply and keep inventory and space costs low, we work with you to develop tailor-made buffer and provision strategies for an ideal interlinking of the assembly areas in your production.

Creation of assembly concepts that meet the requirements 

The right assembly concept for your production

Whether efficiency-driven flow assembly, highly flexible island assembly or stationary construction site assembly – the ideal design of an assembly concept depends heavily on individual parameters and company-specific framework conditions such as the product variance, the product size, the processing times or the required production output. In addition to the implementation of the tried and tested assembly principles, new, innovative concepts can also be developed from their combination and modification. This includes, for example, the modular assembly, which represents an intelligent network of line and island production and thus combines the advantages of the two basic concepts in a highly flexible and efficient solution. Discover together with us how you can ideally align your assembly concept to your internal circumstances as well as to customer and market needs.   

Ergonomic and efficient workplace design

Design of assembly workstations: ergonomic, efficient, digital.

Despite advancing digitization and automation, humans will continue to play a central role in assembly systems in the future. The adaptation of assembly workstations to the individual needs of employees is, therefore, a key success factor. The ergonomic adaptation of assembly workstations enables fatigue-free and health-promoting work and makes a decisive contribution to employee motivation and health. Short reach, easy access to the tools and the strict implementation of the 5S principles also lead to an increase in the performance and work quality of employees. Assistance systems such as exoskeletons or collaborative robots can further support employees in the physical execution of their physical activity. In addition, intelligent pick-by-light systems, augmented reality applications, digital assembly instructions or automated quality checks via cameras offer further potential for efficiently supporting employees in their assembly tasks.

Find out together with us how you can optimally design your assembly workstations and thus increase efficiency, quality and employee satisfaction. 

Resource planning and capacity assessment

Sustainable resource planning for your assembly areas  

The volatile influences of the markets have a direct impact on the capacities required. Based on volume forecasts and growth scenarios, we determine the capacity requirements and work with you to develop an optimal and sustainable resource structure for your assembly areas. To cover the need for skilled workers in the future, we will show you possible resource bottlenecks and work with you to develop strategies and concepts for targeted and efficient staff expansion.  

  • Ramp-up planning

Automation and technology planning in assembly

Systematic analysis of automation solutions

With the advancing digitization, automation technology has also developed rapidly in recent years and offers numerous potentials for increasing quality and efficiency in assembly. In modern smart factories, rigid assembly lines are replaced by highly flexible, driverless transport systems and people are supported in their assembly tasks by collaborative robots (cobots for short). We are happy to advise you with extensive expertise on innovative automation solutions for your assembly. Together with you, we create manufacturer-independent automation concepts for your individual application. In addition to the technical benefits of an automation solution, we naturally also consider aspects of economic efficiency and so-called low-cost automation; standardized, cost-effective automation solutions.

We’ll help you find the right technologies for your challenges.

Practical examples from the field of assembly

Case Study

Plant construction and special plant construction branch


Case study: plant construction

The customer required a high degree of customization of his products. Each product needed to be designed according to the customer’s requirements, making it difficult to segment the assembly according to product properties. The result was generalist workplaces with a low degree of specialization, inefficient material flows and non-transparent assembly structures. Based on detailed analyzes of the product data and parts list information, ifp consulting succeeded in identifying similarities between the products for a customer in the plant construction sector, despite the high degree of customization, and grouping them into assembly segments using cluster analyzes. With the resulting segmentation concept, in addition to increased transparency of the assembly structure, a significant increase in assembly efficiency was achieved through the greater specialization of the workplaces.

Case study: special machine construction

Linking of flow and stand assembly for flexible and efficient assembly in special machine construction

The increasing customization and variety of variants present many manufacturing companies with the challenge of efficiently continuing a synchronised assembly line’s tried and tested principles. If the differences between the products within a line in terms of assembly time and work content become too great, the consistent implementation of a strictly timed assembly line becomes more difficult. A radical departure from the flow principle to the stand principle offers more flexibility, but in most cases, it is associated with enormous process and structural changes. In addition, the change from flow assembly to stand assembly also means numerous losses in efficiency.

ifp consulting was able to successfully support a customer from special machine construction when they encountered these challenges. As a result, the existing cycle assembly was supplemented by a downstream stand area. Standardized work content was mapped within the cycle line, whereas assembly content was handled with a high degree of customization over the stand area. The hybrid use of flow and stand assembly now enables the efficient handling of the standard assembly scopes and offers greater flexibility in order to better cope with the increasing variety of variants in special machine construction.

 

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