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Low Cost Automation Tutorial

#050 About Good "Wide Variety Small Volume Production" Designs

Category : Hints on designing
July16, 2010

Let us take a look at the aspect of LCA designs in regard to "Wide Variety Small Volume" production lines.

We'll begin with sorting of the design process and a flow. [see Fig. 1] "Designing" is a process of decision making (on LCA performance, manufacturing drawings, and information on how to operate) to create "Something" when a need to materialize such "Something" arises. If the design process is commenced forward without giving the proper thoughts, separate design drawings would be need for every production item and the amount of work required will increase exponentially. In actuality, businesses are offering wider variety of products.

[Fig. 1] Fundamental Design Process

For this diversifying needs, there is a design approach called VR (Variety Reduction)

[Table] VR Design Approach
ExplanationA) "Fixed-Variable" Design ApproachB) "Combination" Design Approach
1. Fixed section is composed of a basic specification enabling unit.

2. Variable sections cope with the variety of production items.

3. Fixed + Variable format copes with wide variety production.
1. LCA is expanded into Product/Units/Parts layers.

2. Simplify the Parts and Units into interchangeable design.

3. Combinations of Units and Parts to cope with the wide variety production.
ExamplesThe World Car concept enables the wide variety production scheme by designing the platform (basic body/chassis) as the Fixed section, regional market dependent exterior/interior/accessories as the Variable sections.In a case for Mountain Bikes, the frame and other accessories can be selected to fit the rider to achieve individualized customer fulfillment per product.
LCAFixed section = Base machine
Programming
I/O spec., etc

Variable section = Work holders
Tool units, etc
Linear guides, slide units, etc
- Single axis slide units
- Two axes (XY) slide units
- Interchangeability of above

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