Transforming Automobile Assembly: Experience in Automation and Work Organization

421 Pages·1997·18.025 MB·English

by  T. Fujimoto, U. Jürgens, K. Shimokawa (auth.), Professor Koichi Shimokawa, Dr. Ulrich Jürgens, Professor Takahiro Fujimoto (eds.)

Transforming Automobile Assembly
Springer
Berlin
Heidelberg
New York
Barcelona
Budapest
HongKong
London
Milan
Paris
Santa Clara
Singapore
Tokyo
J
K. Shimokawa . U. iirgens
T. Fujimoto (Eds.)
Transforming
Automobile Assembly
Experience in Automation
and Work Organization
With 140 Figures
, Springer
Professor Koichi Shimokawa
Hosei University
Faculty of Business
2-17-1 Fujimi, Chiyoda-ku
Tokyo 102
Japan
Dr. Ulrich Jurgens
WZB Wissenschaftszentrum Berlin
fiir Sozialforschung
Abt. Regulierung von Arbeit
Reichspietschufer 50
10785 Berlin
Germany
Professor Takahiro Fujimoto
University of Tokyo
Faculty of Economics
7-3-1, Hongo, Bunkyo-ku
Tokyo 113
Japan
ISBN-13:978-3-642-64377 -4
Cip data applied for
Die Deutsche Bibliothek - Cip-Einheitsaufnahme
Transforming automobile assembly: experience in automation and work
organization 1 K. Shimokawa ... (ed.). -Berlin; Heidelberg; New York; Barcelona;
Budapest; Hong Kong; London; Milan; Paris; Santa Clara; Sigapore ; Tokyo:
Springer, 1997
ISBN-13:978-3-642-64377 -4 e-ISBN·13:978-3-642-60374-7
DOl: 10.1007/978-3-642-60374-7
NE: Shimokawa, Koichi [Hrsg.]
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© Springer-Verlag Berlin Heidelberg 1997
Softcover reprint of the hardcover 1st edition 1997
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SPIN:l0502949 68/3020-543210 -Printed on acid -free paper
Contents
1 Introduction ......................................................................................... . 1
(T. Fujimoto, U. Jurgens, K. Shimokawa)
1.1 Main Purpose of this Book .................................................................... .
1.2 International Work Shop for Assembly Automation and
Work Organization ................................................................................ . 2
1.3 Motivation for the Book: Why Study Assembly Automation Now? .... . 4
1.4 Factors Affecting the Choice of Assembly Systems ............................. . 7
1.4.1 Objectives of Assembly Systems .......................................................... . 7
1.4.2 Context .................................................................................................. . 8
1.5 Main Perspectives of the Book ............................................................. . 9
1.5.1 Total System Perspective: Alternatives and Actual Results .................. . 9
1.5.2 Evolutionary Perspective ...................................................................... . 12
1.6 Organization of the Book ...................................................................... . 13
1.7 References ............................................................................................. . 16
2 Concepts and Histories ....................................................................... . 17
2.1 Assembly Automation in Europe - Past Experience and Future Trends 19
(L.-H Hsieh, T. Schmahls, G. Seliger)
2.1.1 Automobile Factory: Production and Assembly ................................... . 19
2.1.2 A Chronology ofInnovations ............................................................... . 20
2.1.3 Innovation Paths ..................................................................................... 35
2.1.4 Conclusions ........................................................................................... . 36
2.2 Basic Trends in the Physics and Economics of Automated Fabrication
and Assembly Operations ..................................................................... . 38
(D. E. Whitney)
2.2.1 Fabrication ............................................................................................ . 38
2.2.2 Assembly ............................................................................................... . 39
2.2.3 Simplified Economic Models ................................................................ . 41
2.2.4 Summary ............................................................................................... . 45
2.2.5 References ............................................................................................. . 45
2.3 Key Characteristics of Assembly Automation Systems ........................ . 46
(J Tidd)
2.3.1 Automation, Complexity and Flexibility .............................................. . 46
2.3.2 Growth of Robotic Assembly ................................................................ . 46
2.3.3 Robotics Technology ............................................................................ . 49
2.3.4 Trends in the UK and Japan .................................................................. . 54
2.3.5 Future Potential of Robotic Assembly .................................................. . 59
VI Contents
2.3.6 References.............................................................................................. 60
2.4 What Do You Mean by Automation Ratio? Definitions by the Japanese
Auto Makers........................................................................................... 61
(T. Fujimoto)
2.4.1 Research Questions ................................................................................ 61
2.4.2 Types of Automation Ratios .... ..... ....... ... .................... .... ...... ... ........... ... 62
2.4.3 Outline ofthe Survey of Automation Ratios.......................................... 63
2.4.4 Results: Different Defmitions of Automation Ratios by Different Firms 65
2.4.5 Implications: MUltiple Indicators for Automation Ratio........................ 67
2.4.6 References.............................................................................................. 69
3 Diversity of Approaches ...................................................................... 71
3.1 Present State and Future Vision of Vehicle Assembly Automation
in Mitsubishi Motors Corporation.......................................................... 73
(Y. Mishima)
3.1.1 Introduction ........................................................................................... . 73
3.1.2 Automation of Assembly Operations .................................................... . 73
3.1.3 Practical Examples ................................................................................ . 79
3.1.4 Conclusions ........................................................................................... . 81
3.2 Development of a new Vehicle Assembly Line at Toyota:
Worker-oriented, Autonomous, new Assembly System ....................... . 82
(A. NUmi, Y. Matsudaira)
3.2.1 Development Background ..................................................................... . 82
3.2.2 Development Progress and Target ....................................................... .. 82
3.2.3 Description of the Development ........................................................... . 83
3.2.4 Results ................................................................................................... . 92
3.2.5 Closing Comment ................................................................................. . 93
3.3 Modular Assembly in Mixed-Model Production at Mazda ................... . 94
(H Kinutani)
3.3.1 Conventional Assembly Line................................................................. 94
3.3.2 Ideal Trim and Final Assembly Line ..................................................... 96
3.3.3 Advantages of Modularization.... ...... ....... ...... ........... ... ... ................ ....... 99
3.3.4 Activities for Modularization ................................................................ 101
3.3.5 The new Hofu Plant ............................................................................... 106
3.3.6 Summary ................................................................................................ 106
3.4 Production of the NSX at Honda: An Alternative Direction
for Assembly Organization ... ........ ...... .... .... ....... ............ ..... ........ ...... ..... 109
(K. Tanase, T. Matsuo, K. Shimokawa)
3.4.1 Introduction ............................................................................................ 109
3.4.2 NSX as an Experiment...... .... .......... .... .... .... ....... ..... ..... ... ........... ...... ...... 109
3.4.3 Challenges to be met by Production Organization................................. 110
3.4.4 Transfer .................................................................................................. 119
3.4.5 Conclusion ............................................................................................. 119
3.4.6 References.............................................................................................. 120
Contents VII
3.5 The Development of an Intelligent Body Assembly System ................. 121
(T. Naitoh, K. Yamamoto, Y Kodama, S. Honda)
3.5.1 Introduction............................................................................................ 121
3.5.2 The Current State of Flexibility ............................................................. 121
3.5.3 IBAS Concepts....................................................................................... 123
3.5.4 Configuration of the IBAS Body Main Line .......................................... 125
3.5.5 Fundamental Technologies ofIBAS ...................................................... 126
3.5.6 Benefits ofIBAS .................................................................................... 131
3.5.7 Conclusion ............................................................................................. 132
3.5.8 References .............................................................................................. 132
3.6 The Opel Production System ................................................................. 133
(P. Enderle)
3.6.1 Reasons for a new Production System ................................................... 133
3.6.2 Characterization .................................................................................... 134
3.6.3 Eisenach Plant: A Model for the Opel Production System .................... 135
3.6.4 First Results............................................................................................ 142
3.7 Platform and Modular Concepts at Volkswagen - Their Effects
on the Assembly Process ........................................................................ 146
(E. Wilhelm)
3.7.1 Introduction ............................................................................................ 146
3.7.2 The VW Platform Strategy ..................................................................... 146
3.7.3 Practical Implementation ...................................................................... 149
3.7.4 Modular Concepts .................................................................................. 150
3.7.5 Future Developments ............................................................................. 153
3.8 Automation at Renault: Strategy and Form ............................................ 157
(F. Decoster, M Freyssenet)
3.8.1 Automation Within a Strategy for Assembly......................................... 157
3.8.2 The Form of Automation ....................................................................... 159
3.8.3 Work Organization ................................................................................. 163
3.8.4 Discussion .............................................................................................. 165
3.9 Building Capabilities in Assembly Automation: Fiat's Experiences
from Robogate to the Melfi Plant.... .... ... ..... ..... ....... ........... ........... .... ..... 167
(A. Camuffo, G. Volpato)
3.9.1 An Evolutionary Approach .................................................................... 167
3.9.2 Evolutionary Phases of Fiat's Automation Strategy.............................. 167
3.9.3 Measures and Methodological Issues..................................................... 168
3.9.4 The First Phase: "Pioneering" Rigid Automation .................................. 169
3.9.5 The Second Phase: "Super" Flexible Automation ................................. 171
3.9.6 The Third Phase: "Realistic", Integrated Automation ............................ 181
3.9.7 Conclusion ............................................................................................. 185
3.9.8 References .............................................................................................. 187
3.10 The Development of a Reflective Production System Layout
at Volvo's Uddevalla Car Assembly Plant ............................................. 189
(K. Ellegard)
3.10.1 Introduction ............................................................................................ 189
VIII Contents
3.lO.2 Planning a new Factory .......................................................................... 191
3.10.3 Efforts to Achieve the Goals: The Evolution of a New Production
System Reflected by the Layouts. ..... ................. ....... ... ........... ... ..... ....... 192
3.10.4 Results .................................................................................................... 205
3.10.5 Final Remarks ........................................................................................ 207
3.10.6 References .............................................................................................. 208
4 Issues and Dynamics ............................................................................ 209
4.1 Strategies for Assembly Automation in the Automobile Industry.. ....... 211
(T Fujimoto)
4.1.1 Introduction ............. .......... ......... .............................. .............. ... .... ......... 211
4.1.2 Types of Assembly Automation Strategy.. ........ ....... ... .......... ....... ......... 211
4.1.3 High-tech Automation Strategy ............................................................. 214
4.1.4 Low-Cost Automation Strategy..... ...... ........ ....... .......... .......... .... ..... ...... 217
4.1.5 Human-Fitting Automation .................................................................... 219
4.1.6 Human-Motivating Automation ............................................................. 226
4.1. 7 Future Prospect: Convergence, Hybridization, and Diversity....... ......... 231
4.1.8 References ....... ..... ........ ........... ......... .......... ........ ....... ............. ....... ......... 236
4.2 From Fixed to Flexible: Automation and Work Organization Trends
from the International Assembly Plant Study........................................ 238
(J P. MacDuffie, F. K. Pil)
4.2.1 Measuring Automation .......................................................................... 239
4.2.2 International Trends in Automation Usage, 1989 - 1993/94.................. 241
4.2.3 Use of Robotics ...................................................................................... 243
4.2.4 Automation use by Department ............................................................. 245
4.2.5 The Role of Flexible Workers ................................................................ 250
4.2.6 Perform ace Implications ........................................................................ 251
4.2.7 Conclusion ............................................................................................. 252
4.2.8 References .............................................................................................. 254
4.3 Rolling Back Cycle Times: The Renaissance of the Classic Assembly
Line in Final Assembly.......................................................................... 255
(U Jurgens)
4.3.1 Introduction ............................................................................................ 255
4.3.2 The Critics of the Assembly Line .......................................................... 256
4.3.3 Learning from Experiences from Longer Cycle Work .......................... 266
4.3.4 A Sustainable Solution? ......................................................................... 270
4.3.5 References .............................................................................................. 271
4.4 Rationalization also Involves Workers - Teamwork in the
Mercedes-Benz Lean Concept ............................................................... 274
(R. Springer)
4.4.1 Teamwork - A Participative Approach to Rationalization .................... 274
4.4.2 New Time Savings, Teamwork and a Continuous Improvement
Process are Elements of a new Labour Policy....................................... 276
4.4.3 Teamwork can be Organized Restrictively of Offensively.......... .......... 278
Contents IX
4.4.4 Higher Demands on Performance are Accepted if the Job is Enriched
and the Group is Genuinely Allowed to Organize its own Workload .... 280
4.4.5 Willingness to Improve Performance Through Self-Organization ........ 283
4.4.6 A Willingness to Cooperate in the Rationalization Process ................... 285
4.4.7 Having Twin Objectives has Stood the Test of Time - Teamwork
is now Being Extended and will be used Widely in Other Areas .......... 287
4.5 Patterns of Work Organization in the German Automobile Industry .... 289
(M Kuhlmann, M Schumann)
4.5.1 Reorganization of Work Until the Beginning of the 90's ...................... 290
4.5.2 The Situation in the Mid 90's: Two Types of Group Work ................... 299
4.5.3 References .............................................................................................. 304
4.6 The Current Social Form of Automation and a Conceivable Alternative:
Experience in France.............................................................................. 305
(M Freyssenet)
4.6.1 The Economic and Social Presuppositions Behind the Current
Processes and Social Forms of Automation ........................................... 305
4.6.2 Compatibilities and Incompatibilities Between the Current Form
of Automation and new Forms of Work Organization .......................... 309
4.6.3 A Process and a Social Form of Automation Aimed at Financial
Performance and Real Skilling of Work are Conceivable and
Achievable in a Localized Way, but can they be Generalized? ............. 313
4.6.4 The Difficlulties of Implementation and the Social Preconditions
for a Generalization of the Process and Social Form of Automation
Already Discussed.................................................................................. 315
4.6.5 Conclusions ............................................................................................ 316
4.7 Worker-Generated Production Improvements in a Reflective
Production System - or Kaizen in a Reflective Production System ....... 318
(K. Ellegard)
4.7.1 Introduction ............................................................................................ 318
4.7.2 Organization and Initiatives for Improvements in Different
Production Systems.............. ...... ...... .... ..... .... ... ........... .......... ................. 3 19
4.7.3 When what there is and what there Ought to be do not Correspond-
Strategies to Solve a Disparity Problem ................................................. 322
4.7.4 The Development of a Worker Controlled Holistic Method to Follow
up Work Performance in Order to Improve Production Conditions ...... 323
4.7.5 General Conclusions .............................................................................. 333
4.7.6 References .............................................................................................. 334
4.8 Advanced Automation or Alternative Production Design?
A Reflection on the new Japanese Assembly Plants and the Alternative
Approach of Volvo Uddevalla ............................................................... 335
(c. Berggren)
4.8.1 Introduction............................................................................................ 335
4.8.2 The Automation Drive of the 1980s and the new Japanese Wave ......... 335
4.8.3 The Uddevalla Option: Skill-Based Manual Assembly
and Increased Customization ................................................................. 338
X Contents
4.8.4 Europe in 1990s - A Return to Manual Assembly................................. 341
4.8.5 References.............................................................................................. 342
4.9 A Misguided Trajectory? Automatically Guided Vehicles in Auto
Assembly ................................................................................................ 344
(K. Mishina)
4.9.1 Introduction............................................................................................ 344
4.9.2 AGVs as a Trajectory ............................................................................. 345
4.9.3 Plant X and the Data .............................................................................. 347
4.9.4 Good News............................................................................................. 350
4.9.5 Bad News ............................................................................................... 352
4.9.6 Real News .............................................................................................. 355
4.9.7 Conclusion ............................................................................................. 358
4.9.8 References .............................................................................................. 359
4.10 Organizational Change and Assembly Automation in the Dutch
Automotive Industry...... ................... ................. .... ..... ..... .............. ........ 360
(J: Benders, B. Dankbaar)
4.10.1 Introduction ............................................................................................ 360
4.10.2 Modem Sociotechnical Design and Lean Production ............ ........ ........ 361
4.10.3 DAF Trucks. ............... ........................................................... ... ..... ........ 364
4.10.4 NedCar ................................................................................................... 368
4.10.5 Discussion .............................................................................................. 375
4.10.6 References .............................................................................................. 377
4.11 Recycling and Disassembly - Legal Burden or Strategic Opportunity? 380
(G. Seliger, C. Hentschel, A. Kriwet)
4.11.1 Legal Framework in Germany ...................................................... ......... 380
4.11.2 Scrap from Automobiles ........................................................................ 382
4.11.3 Ways out of the Problem: Disassembly ................................................. 384
4.11.4 Disassembly Planning ............................................................................ 386
4.11.5 Product Design ....................................................................................... 390
4.11.6 Conclusion ............................................................................................. 393
4.11.7 References .............................................................................................. 393
5 Conclusions and Outlook..................................................................... 395
(u. Jurgens, T. Fujimoto, K. Shimokawa)
5.1 Lessons to be Learnt from the Japanese Style of Production and their
Application to Factory Automation ............................................. .......... 395
5.1.1 Diversity of Strategies Between East and West in the 1980s................. 395
5.1.2 Factory Automation and the Just-in-Time System ................................. 397
5.2 Design Choices for Assembly Systems .................................................. 400
5.3 Outlook .................................................................................................. 405
6 The Authors of the Book...................................................................... 408