Redesign and Re-planning with
io-consultants

As the variation of products and processes increases, so does the complexity of fabrication and assembly systems. As a supplier-independent planning and consulting company, we support our customers in both new design and re-design.

The many years of experience in diverse project work and the broad know-how in many different industries enables us to create integrated solutions for complex organizational and technical tasks in production.

Our services for assembly and production system planning

Quick, flexible and lean

Every needless action affects complex manual or partially automated assembly systems. Coordinated assembly structures increase flexibility, reduce equipment times and permit Lean production logistics. Therefore, periodic detailed review of your work is a good idea.

We offer the following services for this:

  • Determination of the requirements concerning diversity of variations, market dynamics and assembly technologies to be used
  • Evaluation and selection of the assembly concepts eligible for you, e.g. U-form assembly cells, isolated/linked assembly lines, individual workplaces or group/construction site assembly
  • Planning the assembly processes using MTM (Methods-Time Measurement)
  • Floor-space and personnel demand planning

Various factors are considered for work station design/ergonomics evaluation, including employee stress, handling space, noise, light, etc.

  • e.g. by video analysis on work station level
  • Identification of wastes in the assembly process, e.g. difficult positioning or fixation of parts, repeated picking up of tools, problematic movements
  • Evaluation of the value-added portion of total assembly time
  • Derivation of optimization potential

Our services for production system planning

Flexible, agile and effective

Smaller and smaller lot sizes and new technologies are quickly gaining speed in production. Better agility, high adaptability and speed at small inventories and consistent availabilities are needed. The coinciding requirements to flexible production make it more and more important to ensure high system effectiveness in the operation when planning complex production systems. Our services are structured as follows:

First, the planning basis is determined under consideration of product properties such as geometry, piece numbers, technologies and individual process steps, as well as the process. Various features are then used to form product families (e.g. by cluster analysis).

The next step is design of the production system. It examines the individual suitability of various approaches from workshop production or group production, to agile production systems, to systems with cycled serial or flow production. One essential aspect is the manner of linking of individual pieces of equipment (e.g. rigidly by a fixed conveyor, or isolated by autonomous transport systems).

The layouts are planned on workplace and production area level based on this and included in the layout planning on factory level. The planning results can additionally be secured by simulation.

Another service component is derivation of requirements and subsequent transfer to specifications. This results in technical specifications for the invitation of tenders. io-consultants provides experience from a single source, e.g. for special matters of clean-room planning, complex construction requirements, as well as integration and connection to IT-systems (e.g. MES). Profit from coordinated system concepts and smooth integration into the overall logistics, information and building-technical system.

We will review and compare offers received under technical and economic aspects in the tendering and awarding phase, and draw up a price and performance overview based on this. To compare the offers, we will conduct technical discussions with the bidders, compile documents for awarding negotiations, support the awarding negotiations technically and finally develop an awarding suggestion.

During the implementation phase, we will support you in coordinating the different disciplines and associated suppliers, and in coordinating the individual activities with each other. Our tasks include, among other things, review of the technical specifications, support for setup of systems and logistics facilities, tests and acceptances, preparation, execution and monitoring of relocation, as well as monitoring of start-up.

Methods of assembly and production system planning

When planning assembly and production systems, we rely, among other things, on the following methods:

  • Video analysis of assembly work
  • MTM on the design of assembly processes
  • Design for automation/ assembly
  • Process mining
  • Simulation

Selection of the assembly structure and identification of assembly structure and automation potential

The selection of an assembly cell structure depends on demand fluctuations, product features and product variety.
A U-cell offers the option of varying output volume by adjustment of the number of operators. For days with less demand, one employee can perform all assembly steps alone, walking from station to station. Since the last station is adjacent to the starting point, they can immediately start the next job. In I-lines, the employee would have to walk back to the other end of the line, losing valuable time. As the piece numbers increase, a larger group of operators can divide labor and work in flow production from stationary positions.  U-cells are, however, only suitable for smaller products with a length of up to one metre. Longer or bulky products reduce efficiency when passing on the workpiece in a narrow space.
Material provision also plays a role in selection. If a large number of common parts are needed, it is a good idea to provide many of these parts in an integrated push-through rack before the operator. This will be easier to top up by production when all push-through racks are placed in one row.

Automation offers potentials to reduce the unit costs and improve quality. However, certain activities are difficult to solve with standard automation due to material properties or work piece geometry. Individual analysis of the assembly scopes and handling steps are required to solve these issues. Automation inhibitors are identified and customized solutions are developed following this. Finally, costs and benefits are compared.

Please contact us 

Ansprechpartner Fabrikplanung Dr. Christian Barysch
Dr. Christian Barysch Partner Phone: +49 (0) 62 21 / 379-190