Transforming Automobile Assembly

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1 K. Shimokawa U. Jiirgens T. Fujimoto (Eds.) Transforming Automobile Assembly Experience in Automation and Work Organization With 140 Figures Springer

2 Contents 1 Introduction 1 (T. Fujimoto, U. Jiirgens, K. Shimokawa) 1.1 Main Purpose of this Book International Work Shop for Assembly Automation and Work Organization Motivation for the Book: Why Study Assembly Automation Now? Factors Affecting the Choice of Assembly Systems Objectives of Assembly Systems Context Main Perspectives of the Book Total System Perspective: Alternatives and Actual Results Evolutionary Perspective Organization of the Book References 16 2 Concepts and Histories Assembly Automation in Europe - Past Experience and Future Trends 19 (L.-H. Hsieh, T. Schmahls, G. Seliger) Automobile Factory: Production and Assembly A Chronology of Innovations Innovation Paths Conclusions Basic Trends in the Physics and Economics of Automated Fabrication and Assembly Operations 38 (D. E. Whitney) Fabrication Assembly Simplified Economic Models Summary References Key Characteristics of Assembly Automation Systems 46 (J. Tidd) Automation, Complexity and Flexibility Growth of Robotic Assembly Robotics Technology Trends in the UK and Japan Future Potential of Robotic Assembly 59

3 VI Contents References What Do You Mean by Automation Ratio? Definitions by the Japanese Auto Makers 61 (T. Fujimoto) 2A.I Research Questions Types of Automation Ratios Outline of the Survey of Automation Ratios Results: Different Definitions of Automation Ratios by Different Firms Implications: Multiple Indicators for Automation Ratio References 69 3 Diversity of Approaches Present State and Future Vision of Vehicle Assembly Automation in Mitsubishi Motors Corporation 73 (Y. Mishima) Introduction Automation of Assembly Operations Practical Examples Conclusions Development of a new Vehicle Assembly Line at Toyota: Worker-oriented, Autonomous, new Assembly System 82 (A. Niimi, Y. Matsudaira) Development Background Development Progress and Target Description of the Development Results Closing Comment Modular Assembly in Mixed-Model Production at Mazda 94 (H. Kinutani) Conventional Assembly Line Ideal Trim and Final Assembly Line Advantages of Modularization Activities for Modularization The new Hofu Plant Summary Production of the NSX at Honda: An Alternative Direction for Assembly Organization 109 (K. Tanase, T. Matsuo, K. Shimokawa) Introduction NSX as an Experiment Challenges to be met by Production Organization Transfer Conclusion References 120

4 Contents VII 3.5 The Development of an Intelligent Body Assembly System 121 (T. Naitoh, K. Yamamoto, Y. Kodama, S. Honda) Introduction The Current State of Flexibility IBAS Concepts Configuration of the IBAS Body Main Line Fundamental Technologies of IBAS Benefits of IB AS Conclusion References The Opel Production System 133 (P. Enderle) Reasons for anew Production System Characterization Eisenach Plant: A Model for the Opel Production System First Results Platform and Modular Concepts at Volkswagen - Their Effects on the Assembly Process 146 (B. Wilhelm) Introduction The VW Platform Strategy Practical Implementation Modular Concepts Future Developments Automation at Renault: Strategy and Form 157 (F. Decoster, M. Freyssenet) Automation Within a Strategy for Assembly The Form of Automation Work Organization Discussion Building Capabilities in Assembly Automation: Fiat's Experiences from Robogate to the Melfi Plant 167 (A. Camuffo, G. Volpato) An Evolutionary Approach Evolutionary Phases of Fiat's Automation Strategy Measures and Methodological Issues The First Phase: "Pioneering" Rigid Automation The Second Phase: "Super" Flexible Automation The Third Phase: "Realistic", Integrated Automation Conclusion References The Development of a Reflective Production System Layout at Volvo's Uddevalla Car Assembly Plant 189 (K. Ellegard) Introduction 189

5 VIII Contents Planning a new Factory Efforts to Achieve the Goals: The Evolution of anew Production System Reflected by the Layouts Results Final Remarks References Issues and Dynamics Strategies for Assembly Automation in the Automobile Industry 211 (T. Fujimoto) Introduction Types of Assembly Automation Strategy High-tech Automation Strategy Low-Cost Automation Strategy Human-Fitting Automation Human-Motivating Automation Future Prospect: Convergence, Hybridization, and Diversity References From Fixed to Flexible: Automation and Work Organization Trends from the International Assembly Plant Study 238 (J. P. MacDuffie, F. K. Pil) Measuring Automation International Trends in Automation Usage, / Use of Robotics Automation use by Department The Role of Flexible Workers Performace Implications Conclusion References Rolling Back Cycle Times: The Renaissance of the Classic Assembly Line in Final Assembly 255 (U. Jiirgens) Introduction The Critics of the Assembly Line Learning from Experiences from Longer Cycle Work A Sustainable Solution? References Rationalization also Involves Workers - Teamwork in the Mercedes-Benz Lean Concept 274 (R. Springer) Teamwork - A Participative Approach to Rationalization New Time Savings, Teamwork and a Continuous Improvement Process are Elements of a new Labour Policy Teamwork can be Organized Restrictively of Offensively 278

6 Contents IX Higher Demands on Performance are Accepted if the Job is Enriched and the Group is Genuinely Allowed to Organize its own Workload Willingness to Improve Performance Through Self-Organization A Willingness to Cooperate in the Rationalization Process Having Twin Objectives has Stood the Test of Time - Teamwork is now Being Extended and will be used Widely in Other Areas Patterns of Work Organization in the German Automobile Industry (M. Kuhlmann, M. Schumann) Reorganization of Work Until the Beginning of the 90's The Situation in the Mid 90's: Two Types of Group Work References The Current Social Form of Automation and a Conceivable Alternative: Experience in France 305 (M. Freyssenet) The Economic and Social Presuppositions Behind the Current Processes and Social Forms of Automation Compatibilities and Incompatibilities Between the Current Form of Automation and new Forms of Work Organization A Process and a Social Form of Automation Aimed at Financial Performance and Real Skilling of Work are Conceivable and Achievable in a Localized Way, but can they be Generalized? The Difficulties of Implementation and the Social Preconditions for a Generalization of the Process and Social Form of Automation Already Discussed Conclusions Worker-Generated Production Improvements in a Reflective Production System - or Kaizen in a Reflective Production System 318 (K. Ellegard) Introduction Organization and Initiatives for Improvements in Different Production Systems When what there is and what there Ought to be do not Correspond - Strategies to Solve a Disparity Problem The Development of a Worker Controlled Holistic Method to Follow up Work Performance in Order to Improve Production Conditions General Conclusions References Advanced Automation or Alternative Production Design? A Reflection on the new Japanese Assembly Plants and the Alternative Approach of Volvo Uddevalla 335 (C. Berggren) Introduction The Automation Drive of the 1980s and the new Japanese Wave The Uddevalla Option: Skill-Based Manual Assembly and Increased Customization 338

7 X Contents Europe in 1990s - A Return to Manual Assembly References A Misguided Trajectory? Automatically Guided Vehicles in Auto Assembly 344 (K. Mishina) 4.9 A Introduction AGVs as a Trajectory Plant X and the Data Good News Bad News Real News Conclusion References Organizational Change and Assembly Automation in the Dutch Automotive Industry 360 (J: Benders, B. Dankbaar) Introduction Modern Sociotechnical Design and Lean Production DAF Trucks NedCar Discussion References Recycling and Disassembly - Legal Burden or Strategic Opportunity? 380 (G. Seliger, C. Hentschel, A. Kriwet) Legal Framework in Germany Scrap from Automobiles Ways out of the Problem: Disassembly Disassembly Planning Product Design Conclusion References Conclusions and Outlook 395 (U. Jiirgens, T. Fujimoto, K. Shimokawa) 5.1 Lessons to be Learnt from the Japanese Style of Production and their Application to Factory Automation Diversity of Strategies Between East and West in the 1980s Factory Automation and the Just-in-Time System Design Choices for Assembly Systems Outlook The Authors of the Book 408

Process Planning - The Link Between Varying Products and their Manufacturing Systems p. 37

Process Planning - The Link Between Varying Products and their Manufacturing Systems p. 37 Definitions and Strategies Changeability - An Introduction p. 3 Motivation p. 3 Evolution of Factories p. 7 Deriving the Objects of Changeability p. 8 Elements of Changeable Manufacturing p. 10 Factory