Can flexible assembly lines realize mixed-line assembly of multiple products?
5 min readIn the context of today's manufacturing industry increasingly moving towards digitalization, intelligence and personalization, "flexible production" has become an important means for all walks of life to pursue efficient response to market demand. Among them, the flexible assembly line, as a key component of intelligent manufacturing, has attracted much attention for its outstanding ability in multi-product mixed-line assembly.
This article will focus on the core issue of "whether the flexible assembly line can achieve multi-product mixed-line assembly", combining technical principles, system structure, application cases and practical challenges for a systematic analysis to help manufacturing companies understand the true value and implementation points of the flexible assembly line.
1. What is multi-product mixed-line assembly?
In the traditional manufacturing system, an assembly line can often only perform standardized and fixed production for one product. If you want to switch products, you must make complex and time-consuming line adjustments and process resets. This method is certainly efficient in a mass production environment, but in the face of today's market demand characterized by small batches, diversification and personalization, its limitations are becoming increasingly significant.
The so-called mixed-model assembly line refers to the simultaneous or alternating production of multiple models or variants of products on an assembly line without the need to frequently change equipment or manually reorganize workstations. This capability requires the system to have high flexibility, standardized interfaces, configurable control logic and precise scheduling mechanism.
2. Why can flexible assembly lines support mixed-line production?
The reason why flexible assembly lines can support mixed-line assembly of multiple products is mainly due to its following technical features:
Modular workstation design
The flexible assembly line adopts a modular design concept. Each workstation can be regarded as a "functional module" to support the rapid replacement of fixtures, tools and process parameters to meet the operation requirements of different products. Through standardized interfaces, the workstation can complete the rapid switch from product A to product B in a short time.
Introduction of industrial robots and collaborative robotic arms
The robot can perform programmable, multi-process operation tasks. A robot workstation can automatically identify the current product model, switch the operation path and action logic, and flexibly respond to the differences in assembly tasks.
Reconfigurable conveying system
Flexible assembly lines are generally equipped with intelligent conveying systems (such as AGV, circular tracks, flexible chain plates, etc.), which can accurately deliver workpieces to the corresponding workstations according to product models, and realize dynamic material distribution and path optimization.
Intelligent control and scheduling system
Integrate MES (manufacturing execution system), PLC control system and product identification system (such as RFID, QR code, visual recognition) to achieve product-level "identity recognition" and autonomous assembly path planning. Each product can automatically generate an operation process and guide assembly execution based on its production process flow.
Product process database management
A complete product process database system runs behind the flexible assembly line. The process flow, assembly steps and quality standards of each product are stored in the digital system to ensure the consistency and traceability of different models of products in the mixed line process.
3. Analysis of typical application scenarios
New energy vehicle assembly
On a flexible assembly line, multiple new energy vehicles with different configurations (such as standard version, long-range version, high-performance version, etc.) can be assembled at the same time, including body, motor, electronic control and interior components. By identifying the VIN code, the system matches the corresponding assembly program for each vehicle.
Home appliance manufacturing industry
Washing machines, refrigerators, air conditioners and other products often have multiple models and specifications (such as capacity, variable frequency and non-variable frequency, color differences, etc.). Flexible assembly lines allow workers to perform customized assembly according to the model of each device without stopping the line.
3C Electronic Manufacturing
On the same production line, different models of mobile phones or tablets can be mixed and produced. The assembly procedures, tightening force, and testing standards can be automatically adjusted by the system, greatly improving efficiency.
4. Advantages of mixed-line assembly of multiple products
The mixed-line capability of flexible assembly lines brings the following significant advantages to manufacturing companies:
Improve production line utilization
Traditional dedicated lines often need to be shut down for transformation when switching products, while flexible assembly lines can seamlessly connect different products to maximize equipment capacity.
Improve order response speed
When facing personalized orders, customized products or sudden demands, flexible assembly lines can quickly deploy production tasks without frequent scheduling adjustments.
Reducing operating costs
Avoid repeated construction of multiple single product production lines and reduce maintenance and personnel training costs caused by equipment replacement.
Optimize inventory structure
The mixed-line capability allows companies to "produce on demand" according to actual needs, reducing the inventory pressure of raw materials and finished products.
Enhance corporate competitiveness
In the face of highly customized and rapidly iterative market trends, production lines with mixed-line capabilities are more adaptable to future development and help companies take the initiative in the market.
Flexible assembly line can not only realize mixed-line assembly of multiple products, but also is one of the best choices for achieving mixed-line assembly of multiple products. It breaks the limitation of traditional manufacturing that "one production line can only make one product" and becomes the core carrier of manufacturing to achieve "diversification, fast delivery, and high quality". If you plan to build an efficient flexible assembly system to achieve mixed-line production of multiple models, you can start from flexible design, automation integration, and intelligent control in combination with your own product structure, process difficulty, and delivery rhythm, and gradually build an assembly system with strong mixed-line capabilities.
If you are looking for a flexible assembly line solution suitable for mixed-line production of multiple products, we have rich industry experience and technical accumulation, and can tailor efficient and intelligent flexible assembly systems according to your product characteristics, production line requirements, and future expansion plans. Feel free to contact our professional technical team at any time to obtain one-to-one customized solutions and project evaluation services to help you achieve flexible upgrades of production lines and comprehensive improvements in manufacturing efficiency.
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