The article presents a decision support methodology for the selection of a modular reconfigurable assembly system using three-dimensional visualization, component-based simulation, efficiency, and economic analysis methodology. During the design and selection of an assembly system, measurement schemes should be established for determining and understanding design effectiveness. Measurements can be classed into two categories: cost and performance. Understanding assembly production costs is the first step towards increasing profits. The authors have developed an analysis method that integrates factory simulation, overall equipment efficiency (OEE), and economic analysis methods. Cost calculation includes life cycle cost (LCC), cost of ownership (COO), commonly used investment evaluation methods, discounted cash flow techniques, net present value (NPV), and internal rate of return (IRR). The idea is to use these integrated analysis methods in the selection and development of a light assembly system. The development is based on selected industrial standards and the authors’ own experience in assembly system design and simulation. The developed TCO (total cost of ownership) methodology is useful in system supplier and end-user communication; ideally, it is used in the assembly system sales process, it helps in trade-off analysis of the system concepts, and it improves system specification.

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Purpose -The aim of the research was to evaluate the concept that utilizes structured planar substrates based on low temperature co-fired ceramics (LTCC) as a precision platform for the passive alignment of a multimode fiber and wide-stripe diode laser. Design/methodology/approach -Presents the manufacturing process for realisation of 3D precision structures, heat dissipation structures and a cooling channel into the LTCC substrate. The developed methodology for 3D modelling and simulation of the system was used to optimize structures, materials and components in order to achieve optimal performance for the final product and still maintain reasonably low fabrication costs. The simulated optical coupling efficiency and alignment tolerances were verified by prototype realization and characterization. Findings -The achieved passive alignment accuracy allows high coupling efficiency realisations of multimode fiber pigtailed laser modules and is suitable for mass production. Research limitations/implications -Provides guidance in the design of LTCC precision platforms for passive alignment and presents a hybrid simulation method for photonics module concept analysis. Practical implications -The three-dimensional shape of the laminated and fired ceramic substrate provides the necessary alignment structures including holes, grooves and cavities for the laser to fiber coupling. Thick-film printing and via punching can be incorporated in order to integrate electronic assemblies directly into the opto-mechanical platform. Originality/value -Introduces the LTCC 3D precision structures for photonics modules enabling passive alignment of multimode fiber pigtailed laser with high efficiency optical coupling. Demonstrates the hybrid simulation methodology for concept analysis.

Abstract:This article presents a case study in the design of a modular semi-automated reconfigurable assembly system using life cycle cost analysis methodology. To ensure that an assembly system is appropriately designed, system measurement schemes should be established for determining and understanding design effectiveness. Understanding life cycle costs is the first step toward increasing profits. The authors are developing an analysis tool that integrates Overall Equipment Efficiency (OEE), Cost of Ownership (COO), and other analysis methods to improve the design of flexible, modular reconfigurable assembly systems. The development is based on selected industrial standards and the authors' own experience in modular assembly system design and simulation. The developed TCO (Total Cost of Ownership) methodology is use&] in system supplier and end-user communication and helps in trade-off analysis of the system concepts.

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