Aircraft Assembly Snags: Human Errors or Lack of Production Design?

Alogla, Ageel Abdulaziz; Alruqi, Mansoor

doi:10.3390/aerospace8120391

Cited by 7 publications

(3 citation statements)

References 22 publications

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“…Human error is the most common cause of failures in automated production lines. The elimination of this factor is described by Alogla et al in their paper [13].…”

Section: Literature Reviewmentioning

confidence: 97%

Poka Yoke in Smart Production Systems with Pick-to-Light Implementation to Increase Efficiency

Trojanowska,

Husár,

Hrehova

et al. 2023

Applied Sciences

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Product assembly is often the last step in the manufacturing process. This task is usually performed by an assembly worker who needs to have practical experience and expertise. For complex products, the assembly may require a long time to study assembly plans. This paper presents a custom-designed Pick-to-Light system using Poka Yoke principles to make this activity easier. The created modular system with two-stage verification serves to guide the assembler precisely. It shows him on the display which parts he should use in a strictly defined assembly step. Our proposal aims to shorten assembly time and reduce the number of errors, which was supported by a case study in a small company with 30 employees. After analysing the data, we can declare that the proposed system significantly reduces the time required for assembly from 7 to 35% and reduces the error rate by 35%. The solution is scalable and flexible, as it can be easily adapted to display assembly steps for a different product.

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“…Human error is the most common cause of failures in automated production lines. The elimination of this factor is described by Alogla et al in their paper [13].…”

Section: Literature Reviewmentioning

confidence: 97%

Poka Yoke in Smart Production Systems with Pick-to-Light Implementation to Increase Efficiency

Trojanowska,

Husár,

Hrehova

et al. 2023

Applied Sciences

View full text Add to dashboard Cite

show abstract

“…In automated production lines, human error is the most common cause of failures. The elimination of this factor is described by the authors in the paper [12]. 3 In the presented article, we are focusing on the possibility of using Pick to Light to eliminate errors caused by operators.…”

Section: Literature Reviewmentioning

confidence: 99%

Poka Yoke in Smart Production Systems with Pick to Light Implementation to Increase Efficiency: A Study

Trojanowska¹,

Husár²,

Hrehová³

et al. 2023

Preprint

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Product assembly is usually one of the last steps in the entire production process. This activity is typically entrusted to assembly workers because it is generally not possible to automate every type of product. For complex products, assembly can take a long time until the fitter learns the procedure and is able to assemble the product on his own. This contribution presents a cus-tom-developed system that enables controlled assembly of the extruder and can be used for complex and diverse products. The system serves to guide the fitter precisely and shows him which part to use at which time. The proposed system will show and describe on the display all necessary assembly steps and parts. Two-step verification is used to ensure that the correct part is picked from the stack. The contribution is supported by the implementation of a case study in a small company with a sample of 30 employees, which demonstrates that the proposed system shortens the extruder assembly time and significantly reduces the error rate. The presented solution is scalable and flexible, as it can be easily adapted to display the assembly steps of another product.

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“…Despite the historical trend to increase automation in manufacturing (Dinlersoz & Wolf, 2018), manual assembly systems still play an essential role, particularly in some contexts where there is a high level of complexity and variety in production. This is the case in the aerospace industry which heavily relies on human work (Alogla & Alruqi, 2021; Beuß et al, 2019; Judt et al, 2020). Even as the proportion of monotonous and repetitive tasks continues to decline because of automation, we can expect that complex manual assembly will still need a human's skills set.…”

Section: Introductionmentioning

confidence: 99%

Applying AcciMap and STAMP to the analysis of human error in complex manual assembly

Torres

Nadeau

Landau

2022

Hum Ftrs & Erg Mfg Svc

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In sectors such as aerospace manufacturing, human errors in the assembly of complex products can negatively impact quality, productivity, and safety. Until now, the analysis of assembly errors has focused more on the immediate human‐system interface and less on broader organizational factors. This article presents a case study‐based analysis of assembly errors in the aeronautical industry using the systemic methods AcciMap and Systems‐Theoretic Accident Model and Processes (STAMP). We seek to provide the company with elements to build a quality improvement strategy that considers human factors and ergonomics from a systemic perspective. The data and information necessary to conduct the analysis came from a project carried out at an aerospace manufacturing facility over a period of 12 months. The team had direct and recurrent access to primary data sources and communication with various stakeholders. A total of 31 influencing factors were identified with AcciMap at different levels within the manufacturing system. STAMP made it possible to model the sociotechnical control structure of the assembly process and identify several control flaws leading to hazards. The analysis shows that systemic methods require a high level of understanding of the manufacturing system and access to relatively high amounts of data and information. Therefore, direct contact with the field and stakeholders is crucial. Training quality specialists on systemic methods could support its use and help to close the gap between theory and practice. Globally, the field of quality in manufacturing could benefit from using systemic methods when deemed necessary.

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Aircraft Assembly Snags: Human Errors or Lack of Production Design?

Cited by 7 publications

References 22 publications

Poka Yoke in Smart Production Systems with Pick-to-Light Implementation to Increase Efficiency

Poka Yoke in Smart Production Systems with Pick-to-Light Implementation to Increase Efficiency

Poka Yoke in Smart Production Systems with Pick to Light Implementation to Increase Efficiency: A Study

Applying AcciMap and STAMP to the analysis of human error in complex manual assembly

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