Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2009. / This thesis details the conceptual design of a fixture-based, reconfigurable, automated spot welding system aimed at manufacturing various sub-assemblies of circuit breakers. The welding operations are currently done using manual welding equipment, making this stage of the assembly process highly labour intensive. A range of product models and variants are assembled in quantities requiring frequent change-overs. Low-cost automation within a developing country’s manufacturing industry, more specifically within the Republic of South Africa, is the target context. The chosen design restriction, of incorporating a part fixturing design approach, distinguishes this research from F. S. D. Dymond’s work, who addressed the same problem while restricted to a fixtureless assembly approach. A conceptual layout design was developed to address part feeding, manipulation, transportation, fixturing and welding requirements, for an entire breaker model range. A simulation model for three possible layouts of the selected conceptual design provided a means to investigate each layout’s ability to tolerate and balance variation in production requirements, and to establish objective comparative performance data. This showed that the optimal configuration consists of four single loop layout systems. The thesis concludes that the final concept possesses the flexibility to produce the primary product range. Reconfiguration for production beyond this range is assisted by the modular nature of the layout. Ultimately, a reconfigurable design should focus on a properly selected base of core product ranges, providing an expandable and reusable system. The system can be supported by manual assembly stations which handle highly variant, incompatible product ranges.

Thesis (MBA)--Stellenbosch University, 2002. / ENGLISH ABSTRACT: This document describes the different possibilities of Low Cost Intelligent Automation (LCIA)and process analysis for companies in the processing industry. These techniques can be used in production and assembly to reach a higher productivity and to maintain the company's competitiveness. Productivity is very important for any company, because it influences the profit. LCIA means using cheap solutions to automate processes in assembly and production. Cheaper machines payoff much faster. This is important, because life cycles are becoming shorter and shorter. With LCIA more manual processes can be automated. This is an advantage especially in countries with high labour costs. Process analysis helps to optimise processes in a company. To reach this goal it is essential to analyse processes systematically. This helps to gather detailed information about manufacturing defects and where they originated from. With these information it is much easier to eliminate the source of error and to reduce the number of defective products. Less errors in a production process lead to higher quality and productivity. The company "Festool GmbH Deutschland" serves as an example for using the described methods. The presented examples for LCIA are simple solutions to automate manual processes in the assembly division. The process of a fully automated machine serves as an example to illustrate the different aspects of a process analysis in this company. The methodologies presented in this document can be used to achieve improvements especially in productivity. Therefore any company coming from a labour intensive industry should think about integrating LCIA and process analysis into their continuous improvement strategy. / AFRIKAANSE OPSOMMING: Hierdie dokument beskryf die verskillende moontlikhede van Lae Koste Intellegente Automasie (LKIA)en die proses analise vir maatskappye in die vervaardiging industrie. Hierdie metodes kan gebruik word in produksie en montering om hoër produktiwiteit te verkry sowel as die maatskapy se mededingendheid te handhaaf. Produktiwiteit is baie belangrik vir enige maatskappy, want dit beïnvloed die winsgewindheid. LKIA beteken die gebruik van goedkoop oplossings om prosesse te automatiseer in montering en produksie. Goedkoper masjiene word vinniger afbetaal. Dit is belangrik, want die lewenssiklus van beide produkte en masjiene word al korter. Met LKIA kan meer handprosesse ge-automatiseer word. Dit is 'n voordeel veral in lande met hoë arbeidskostes. Proses analise help om die prosesse in 'n maatskappy te optimiseer. Om hierdie doel te bereik is dit belangrik om prosesse sistematies te analiseer. Bogenoemde help om gedetaileerde informasie in te samel rondom vervaardigings defekte sowel as die oorsprong daarvan. Met hierdie informasie is dit makliker om die oorsprong van foute uit te skakel en om die getal foutiewe produkte te verminder. Minder foute tydens die vervaardigings proses ly tot 'n hoër kwaliteit en produktiwiteit. Die maatskappy "Festool GmbH Deutschland" dien as 'n voorbeeld vir die gebruik van die beskryfde metodes. Die voorgestelde voorbeelde vir LKIA is eenvoudige oplossings om die handprosesse in die monterings afdeling te outomatiseer. Die proses van 'n ten volle ge-automatiseerde masjien, dien as 'n voorbeeld om die verskillende aspekte van proses analise in hierdie maatskappy te illustreer. Die metodologie wat gebruik is in die dokument, kan gebruik word om verbeteringe veral in produktiwiteit te bewerkstellig. Dus kan enige firma in 'n arbeidsintensiewe industrie gebruik maak van die integrasie van LKIA en proses analise in sy deurlopende verbeterings strategie.

published_or_final_version / abstract / Industrial and Manufacturing Systems Engineering / Doctoral / Doctor of Philosophy

Report covers June 1, 1976-July 31, 1978. / Each v. has also a distinctive title. / National Science Foundation. Grant NSF/RANN APR76-12036 National Science Foundation. Grant DAR78-17826

Report covers June 1, 1976-July 31, 1978. / Each v. has also a distinctive title. / National Science Foundation. Grant NSF/RANN APR76-12036 National Science Foundation. Grant DAR78-17826

Report covers June 1, 1976-July 31, 1978. / Each v. has also a distinctive title. / National Science Foundation. Grant NSF/RANN APR76-12036 National Science Foundation. Grant DAR78-17826

Report covers June 1, 1976-July 31, 1978. / Each v. has also a distinctive title. / National Science Foundation. Grant NSF/RANN APR76-12036 National Science Foundation. Grant DAR78-17826

Report covers June 1, 1976-July 31, 1978. / Each v. has also a distinctive title. / National Science Foundation. Grant NSF/RANN APR76-12036 National Science Foundation. Grant DAR78-17826

Report covers June 1, 1976-July 31, 1978. / Each v. has also a distinctive title. / National Science Foundation. Grant NSF/RANN APR76-12036 National Science Foundation. Grant DAR78-17826

Report covers June 1, 1976-July 31, 1978. / Each v. has also a distinctive title. / National Science Foundation. Grant NSF/RANN APR76-12036 National Science Foundation. Grant DAR78-17826