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Systematic forecast of human reliability in manual assembly operations in serial production

系统预测批量生产中手动装配操作的人员可靠性

基本信息

批准号：
251787698
负责人：
Professor Dr.-Ing. Robert Refflinghaus
金额：
--
依托单位：
Fachgebiet Qualitäts- und Prozessmanagement
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2014
资助国家：
德国
起止时间：
2013-12-31 至 2017-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/251787698?language=en
关键词：
Systematic forecast human reliability manual

项目摘要

Assembly plays a leading role in the German economy, especially in terms of added value. Depending on product characteristics assembly operations take up to 70 % of the total production time. In recent years, shorter product life cycles and increasing quality requirements of customers led to increasing demands also for the planning process of manual assembly operations.A major goal of quality planning deals with creating strong production processes and reducing the number of errors in production. Transferred to the field of manual assembly processes, this means, besides mastering the technical complexity, also to reduce the human error probability of the employee. The early detection of quality-critical operations therefore is a key element for generating stable and efficient production processes.The evaluation of weaknesses of the production process is usually limited to technical and economical fields. Currently, the planning process of manual assembly processes is primarily focused on an optimization of time scheduling. For this purpose, assembly planners generally use systems of predetermined times for calculating the time that is required to perform a manual assembly operation. Despite of first scientific approaches developed in the previous project MTQM a systematic consideration of human reliability in assembly operations so far is neglected in the operational practice.In this research project, a method will be developed that has the potential to predict human error probabilities in manual assembly operations systematically. The starting point of the development process are the results of the previous project MTQM and also process analyses created by using systems of predetermined times. In addition to the calculation of predetermined times, these process analyses are used to assess the complexity and thus also the error rate of individual sequences of action of manual assembly operations by determining cue motion values for individual task items. With the gained knowledge a systematic procedure for evaluating human reliability in manual assembly operations will be developed. The above mentioned procedure will be based on an Expert System For Task Taxonomy, which for this reason is especially adapted to the certain characteristics of the considered application field. As the human reliability of manual assembly operations is strongly affected by learning curve effects, the influence of experience of the employees and its impact on the amount of resulting error probabilities will also be examined while developing the new method. Due to the prospective determination of human reliability in manual assembly operations the assembly planner will be able to implement necessary adjustments already before start of production. With this procedure costly redesigns during ongoing operations can be avoided.

装配在德国经济中发挥着主导作用，特别是在附加值方面。根据产品特性的不同，装配操作占总生产时间的70%。近年来，随着产品生命周期的缩短和客户对质量要求的不断提高，对手工装配作业的计划过程的需求也越来越大。质量计划的一个主要目标是创建强大的生产过程并减少生产中的错误数量。转移到人工组装流程领域，这意味着除了掌握技术复杂性外，还可以降低员工的人为错误概率。因此，及早发现质量关键操作是产生稳定和高效生产流程的关键因素。对生产流程弱点的评估通常仅限于技术和经济领域。目前，手工装配工艺的规划过程主要集中在时间调度的优化上。为此，装配计划员通常使用预定时间的系统来计算执行手动装配操作所需的时间。尽管在先前的MTQM项目中开发了第一批科学方法，但到目前为止，在操作实践中忽略了对装配操作中人的可靠性的系统考虑。在本研究项目中，将开发一种有可能系统地预测手动装配操作中人的错误概率的方法。开发过程的起点是先前项目MTQM的结果，也是通过使用预定时间的系统创建的过程分析。除了计算预定时间外，这些过程分析还用于通过确定各个任务项的线索运动值来评估手工装配操作的各个动作序列的复杂性，从而也评估各个动作序列的错误率。利用所获得的知识，将制定一套系统的程序，用于评估人工装配作业中的人的可靠性。上述程序将以任务分类专家系统为基础，因此，该系统特别适合所考虑的应用领域的某些特点。由于人工装配操作的人的可靠性受到学习曲线效应的强烈影响，在开发新方法时，还将检查员工经验的影响及其对所产生的错误概率的影响。由于人工装配操作中人的可靠性的预期确定，装配计划员将能够在开始生产之前就实施必要的调整。有了这个程序，就可以避免在正在进行的操作中进行昂贵的重新设计。