Decomposition of automotive manufacturing machines through a mechanism taxonomy within a product lifecycle management framework

The automotive sector as with other manufacturing industries is under continual pressure from the consumer to deliver greater levels of product customisation at a higher quality and at reduced costs. Maintaining market position is therefore increasingly determined by a company's ability to innovate design changes quickly and produce greater numbers of product variants on leaner production lines with shorter times to market. In response manufacturers are attempting to accommodate product customisation and change through the use of reconfigurable production machines. Besides the need for flexibility, production facilities represent a significant investment for automotive manufacturers which is increasingly critical to commercial success; consequently the need to reduce costs through the reuse of assembly and manufacturing hardware on new product programs is becoming crucial. The aim of this research is to enable production machines to be more easily and cost effectively built and subsequently reconfigurable through the adoption of a component-based approach to their implementation utilising virtual manufacturing tools such as Product Lifecycle Management (PLM). It is suggested that through the decomposition of manufacturing machines into standardised mechanisms and their associated data structures a revised business model can be defined. The mechanisms are classified and deployed as part of a consistent integrated data structure that encompasses product, process and plant information. An objective is to properly integrate manufacturing data with more established Product Data Management (PDM) processes. The main areas of research reported in this article are, (1) development of a method for identifying and mapping data producers, consumers and flow, (2) development of standardised data structures for the management of manufacturing data within a PLM tool, (3) development of a taxonomy for the decomposition of manufacturing and assembly lines into a library of standard physical, logical and structural mechanisms and their associated interfaces. An automotive OEM case study is presented to illustrate the classification and management of production mechanisms focusing on an engine assembly line.