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Chapter 1: Introduction
1. Objective
2. Brief Introduction
According to Henry Ford, there are three principles of assembly where are:
a) Place the tools and the men in the sequence of the operation so
that each component part shall travel the least possible distance
while in the process of finishing.
b) Use work slides or some other form of carrier so that when a
workman completes his operation, he drops the part always in
the same place--which place must always be the most
convenient place to his hand--and if possible have gravity carry
the part to the next workman for his operation.
c) Use sliding assembling lines by which the parts to be assembled
are delivered at convenient distances.
A car seat is the chair used in automobiles. Most car seats are made from inexpensive
but durable material in order to withstand as much use as possible. In Fuji car seat line
assembly, the operator need to choose the part for the car seat manually that come to
their station where it is depend on the type of the car seat. Before all the part being
assemble to become one complete seat, the small parts are assemble at subassembly
line. After the small part completely assembled, it is bring to the car seat frame line
assembly in order to assemble it become one car seat. So, this has led the operators
forced to use more energy because not only assemble the small part, but they had to
choose the small part that same type of the seats that come to their station. A car seat is
the chair used in automobiles. Most car seats are made from inexpensive but durable
material in order to withstand as much use as possible. Assembly block diagram
shown below:
3. Purpose
The purpose of our project is, to reduce the work that have been done of the
operator since they need to find the type of the small part that are same with the
seat frame type that come to their station. So, in order to reduce this problem,
we done improvement in the line assembly by applying the artificial intelligent
system such as fuzzy logic, and artificial neural network (but we will use
knowledge base).
Chapter 2: System
As mentioned in previous chapter, the system designed is to give intelligence to the system
especially in deciding a program that going to use for clamping and welding process
according to specifics seat frame grade and model.
2.1 Flowchart
2.2 Explanation
In Fuji Seats Malaysia Sdn Bhd, every seat frame has its different design and welding
point according to every specified model. It means that every seat model has it specific
designs and welding point area.
According to the flow chart, the system starts when the operator placed the seat frame
manually into jig. As mentioned, every seat model has its special design. So that, the jig is
designed consist with the sensor located in specific area that can differentiate and recognized
the seats design and model. After the sensor detect the frame model, the system then will
search the data in the data base. The system will proceed by selecting the setting for that
model if the sensor detected as the frame placed into jig. If not, the operator needs to re-place
the frame into the jig until the system recognized the seat model. The system then will
proceed if the sensor detects the seat model by choosing the setting for next process. After the
setting choose, the system then proceed to choose the setting for clamping and welding
process for the model that already recognized by system. After the system executes the data,
the machine then will clamped and welding the frame as data choose. After the process
finished, the jig will release the clamped and the seat frame will take out from jig manually by
an operator.
To assemble next seat frame but with different model than previous model, the
operator didn’t have to reset the system because the system will recognized the seat model
and grade by itself without human control.
2.3 Diagram
Diagram shows the layout of seat frame production line. As shown, it is consist with storage
area, seat assembly line, sub-assembly line, seat frame assembly line and rework area. The
device that designed will be implemented into seat frame assembly line. Seat frame assembly
line is the section where all parts from sub-assembly line were combined and weld. Sub-
assembly line basically including welding and combined raw material into seat frame sub
component. The finishes good from sub-assembly line then will supply to seat frame
assembly line from fabricate seats according to production model sequence. The finish
product from seat frame then will follows rework process before supply to seat assembly line.
Chapter 3: Simulation
All sources including coding, working simulation and project file can be seen in the report
CD.
3.1 Method
There are 5 type of seat frame that can be recognize by this system. They are:
As being explained by the previous chapter, this system will intelligently detect
the type of the seat frame that being inserted into the starting point (J). Then it
will intelligently change the clamping and welding point according to the
inserted seat frame type. Basically, this system will move from the starting
point to the clamping point and lastly to the welding point. To differentiate
each of this different point, when the seat frame had already passed each of the
point, the RFID code will be modified. This is because, if there are any defect
occur in one of this 3 point, the system can intelligently reinserted the seat
frame to the specific point (where the defect occur) without having to go
through all the previous station. This will reduce production time and it also
will increase productivity.
At station J, the RFID sticker on the seat frame will be scanned and analyzed
by the station. If the output is just like the column J on the table 3.1.1 it means
that each of the model does not going through any of the station yet, the
clamping and welding point will be assign according to the setting for each of
the model. But if the output is just like column K and column L in the table, the
clamping and welding point will be different according to each of the model
respectively. By doing this, the system can know the specific clamping and
welding point that each and every model need without any problems.
a. Forward chaining
b. Backward chaining.
But in this project, we will use forward chaining as the main principal for our
systems. Before building the forward chaining structure, we need to create
inference chain for all data that we have.
Inference Chain
Example of the cycle that occur inside of this system:
T J F T J F T J F
K Q H K Q H K Q H
M A M C A M
A =T A =T A =T
DATABASE
T J F
K Q H
C A M
Knowledge Based
F&K=M
A&J=F
A =T
C=Q
G
B
C
H
D
a. High
b. Low
G = Button to start the operation after the RFID code being inserter into the “A”
H = Image display of the model and determining eheter the model is valid or not
in the database
Simulation
4. Simulation output for seat frame that already pass K (clamping) station
5. Simulation output for the invalid model in the database
2. Recommendation
1. Improved the system detection.
2. Include the placement of frame that manually do by the operator now, in the
system so the assembly line is fully done by the system.
3. Improved selection program for different type of car seat frame.
4. Improved the assembly time of key workstation.
4-BMFA/2
ARTIFICIAL INTELLIGENCE
(BMFA 4423)
PREPARED BY:
PREPARED FOR: