Market turbulence forces assembly plants to constantly adjust their production volume of products, variants and quantities. At the same time, assembly plant managers must protect long‐term investments in the flexible assembly system. For reconfigurability and agility the best solution is the modular semi‐automatic approach by combining flexible automation and human skills. It gives managers possibility to adjust volume by adding new modules or to automate the manual tasks step by step. The control of material handling and information flow in the agile assembly system is important. To keep flexibility, the combination of an intelligent pallet, i.e. use of escort memory, carrying a single product together with other hardware providing paperless production even supports a lot size of one. The article shows how to create flexible capability and capacity in the final assembly systems.

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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.

In the Eureka research project FAMOS-HIPS, a consortium of manufacturing companies, assembly system suppliers and research institutes has developed a new type of assembly system for lightweight products, including mobile phones, consumer electronics, and car components. HIPS stands for human integrated production system, so a primary objective is to enable the production team to adapt its work environment and methods to achieve greater efficiency. The HIPS system combines automated and manual workstations with automatic material flow, which dramatically reduces the number of repetitive tasks for operators. In addition, the operator of each manual workstation can personalize it to optimize his or her ergonomic environment, changing the working configuration, e.g. working height and light level. Buffering features in the system then allow operators to work at their own pace. The greater variety of tasks, improved comfort and other benefits are reflected in higher quality and efficiency. New solution for the assembly of lightweight productsA modular production system for the assembly or disassembly of lightweight items is enabling manufacturers to adapt rapidly to changing market conditions by updating products or bringing in next-generation models without investing in new equipment. Production teams can configure material flow in the plant the way they want it and adapt each workstation to their personal preferences. Results to date show efficiency benefits and indicate that short production runs -even batch size one -can be made economic. The FAMOS-HIPS project links the efforts of ten companies and research centres in five countries and is targeted at goods such as mobile phones, consumer electronics and automotive components. Activities include organizational psychology, manufacturing technology, automation and industrial software, and involve four end users.The key element of the system is physical and logical flexibility. Physical flexibility is achieved by changing the number of assembly stations or by modifying their features. Assembly stations, manual or automatic, that can be added or changed to an existing system 298

This article describes a study that has been made on the automation of deburring in a foundry. Circular castings weighing up to 20kg are deburred before delivery in order to make them fit into machining cells. The maximum production rate of the cylindrical castings on the foundry line is one casting every ten seconds. However, the castings are produced in small batches, typically ranging from 100 to 1,000. After casting and integrated sand blasting and cooling chambers, the castings are transferred further on a conveyor belt. Deburring is today done manually by lifting and pressing against different grinding and deburring machines. Bins and forklifts are used in transport and storage of castings, from production line to deburring and shipment.