Time estimation method for manual assembly using MODAPTS technique in the product design stage

Abstract

This paper aims to propose an accurate and quick assembly time estimation method using the modular arrangement of predetermined time standards in the product design stage. It describes a classification of 2382 assembly operations that are incurred in manually assembling consumer electronics such as air conditioners, washing machines and refrigerators, and a method of choosing representative motions comprising work elements by examining the frequency distribution of the assembly operation's motions. It then presents criteria for assigning time values associated with the movement of the representative motions using the design factors employed in design for assembly and the layout factors of an assembly line. A case study then presents the practicality of the method, the statistical results of which indicate that the proposed method would be accurate enough for practical purposes.

Application of The MODAPTS Method with Innovative Solutions in The Cement Packing Process

“…MODAPTS is defined as a procedure for improving productivity and establishing time standars as a result of the description and classification of the movement given to carry out a series of operations and provide predetermined amount of time predefined for each movement [11]. Industrial and commercial companies have accepted MODAPTS as a valid and useful method as a predeter-mined time system standard [8]. In the MODAPTS method, human movement is classified into 21 types, and is assigned a standard time number as a constant value for each existing movement [12].…”

“…MODAPTS library is a collection of databases that contribute with work elements and working hours, so in the process a product designer can use the estimated work time so that no whole assembly time changes are needed, and this method can decrease re-estimation time [7]. The MODAPTS analysis translates assembly motions into element class codes and time values through video examination [8]. This research will reveal a number of common features of MODAPTS and its applications in the packing process at the cement plant in particular to reduce the waste of working time that causes the production target is not achieved.…”

A Novel Method for Acquiring Engineering-Oriented Operational Empirical Knowledge

“…The operation is difficult to be accurately represented and quantitatively analyzed by direct observation [24]. The specific motion analysis tool is exploited to describe and explain the worker's operation [9]. The result of motion analysis can be used as the foundation of motion elicitation in the next stage.…”

“…Step 2 (motion analysis). The MODAPTS analysis can translate the welding operation into basic motion element class codes and time values through video examination [9]. For example, in an assembly process, the operator's motion sequence includes "move the left hand to the component," "get the component," "move the component," and "put the component," which are assigned the codes M3, G1, M3, and P1, respectively.…”

“…The OEKA integrates motion analysis, motion elicitation, and intent analysis. First, the worker's specific operation process is divided into basic motion elements by means of modular arrangement of predetermined time standards (MODAPTS), which is a system used to analyze the performance of manual work [9]. Second, we combine the motion elements with scenario factors to establish the scenario model, and then the algorithm of variable precision rough set (VPRS) is used to extract the critical motion of skilled technicians.…”