Video-based analysis of potentials


Ineffective assembly processes are one cause of productivity losses in assembly lines. There may be different reasons for the type of ineffectiveness incurred: poorly-organized assembly processes, long distances between the various stations, high rolling stocks, etc. However, it is very difficult to quantify these processes simply by observing them. For this reason, Fraunhofer IPA has developed a video analysis tool, which enables assembly process to be rapidly evaluated and divided into three categories – added value, non-productive work and ineffectiveness. A graphic representation clearly depicts the proportion of each type of movement.

Video analysis procedure

  1. Analysis of the most common assembly processes
  2. Determination of the assembly processes with the highest savings potentials
  3. Video analysis recording
  4. Mutual analysis with workers
  5. Recommendations for optimization and documentation

Aims and benefits of a video analysis

The main objective of a video analysis of assembly processes is to obtain sound information about the savings which can be made by optimizing existing assembly lines.

The following applies for all optimization processes: ineffectiveness has to be completely eliminated in the new assembly system. This is often achieved by designing assembly stations ergonomically, reducing the distance between workstations and optimizing the material supply.

The proportion of non-productive work can be reduced by using multi-spindle screwdrivers with an automated screw feed, for example, or by partially automating sub-processes. Optimizing access to assembly components also reduces the time wasted on non-productive work.