Process planning and assembly design

Choosing the right assembly structure has a significant impact on the cost and flexibility of a system. An inseparable part of efficient assembly systems is low-cost yet optimal supply logistics. We design all aspects of assembly and logistics, from the superordinate system level, through workplace design, to technical and organizational processes. Our projects concerned with planning new or optimizing existing systems include the methodical and in-depth recording of processes and data and the early validation of our planning results through simulation.

Planning assembly systems

  • Selecting the right assembly structure: meeting requirements & taking a cost-benefit oriented approach
  • Classical assembly line planning according to lean line design
  • Designing and dimensioning stand-alone, island or modular matrix assembly systems for complex and varied products
  • Layout planning
  • Ergonomic workplace design
  • Planning devices and equipment
  • Choosing and designing cyber-physical / digital assistance systems for workers
  • Validating planning results by simulating material flows
  • Cardboard engineering
  • Assistance with implementation and start-up

Logistics planning

  • Choosing the right material supply strategies (e.g. Kanban, JIT, shopping cart, point of use provider)
  • Dimensioning the supply logistics
  • Determining the necessary storage steps
  • Selecting and designing logistics and transport means
  • Validating planning results by simulating material flows

Process recording and data analysis

  • Methodical process recording
  • Video analysis to identify where wastage occurs
  • Data analysis with conventional analysis methods and modern data analytics techniques
  • Networking different data sources and, if appropriate, external sensors for generating data

Process and product design

  • Assembly and automation-oriented product design (Design for Assembly and Design for Automation DfA)
  • Analyzing automation potential
  • Derivation of assembly priority graphs
  • Designing technical and organizational processes
  • Deriving ideal assembly sequences

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Planning assembly operations

Do you want to optimize your assembly line or plan a new one? Fraunhofer IPA offers end-to-end solutions for an efficient, cost-effective assembly process.

Modular matrix assembly

High numbers of variants, fluctuating quantities, uncertain future prognosis? Modular assembly systems are reconfigurable and ensure efficient production in a volatile business environment.

Digital transformation in assembly

Can assembly processes be optimized through digitization? Which data are required to plan and optimize assembly operations? Do you need to record and evaluate data? Fraunhofer IPA provides targeted support with the digitization and data-driven optimization of your assembly processes.

Assembly automation

Based on the experience we have gained over many years, we develop fully or partially automated solutions for your assembly requirements, either for you or together with you.

Factory planning and production management

Factory planning and production management play a major role when a company wants to create value.