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Remanufacturing, disassembly…..

Remanufacturing, disassembly…. 2004. 3. 20. 토 김 해 중. Papers. About Remanufacturing. Remanufacturing: The next great opportunity for boosting US productivity From Garbage to Goods: Successful Remanufacturing Systems and Skills Disassembly analysis through time estimation and other metrics.

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Remanufacturing, disassembly…..

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  1. Remanufacturing, disassembly….. 2004. 3. 20. 토 김 해 중

  2. Papers About Remanufacturing • Remanufacturing: The next great opportunity for boosting US productivity • From Garbage to Goods: Successful Remanufacturing Systems and Skills • Disassembly analysis through time estimation and other metrics Business Horizons 46 (2003) 41-46 Ron Giuntini, Kevin Gaudette Executive Director, OEM Product-Services Institute, Lewisburg, Pennsylvania PhD Candidate in Operations and Decision Technologies, Kelley School of Business, Indiana University, Bloomington Business Horizons, 43 (2000), 55-64 Geraldo Ferrer*, D. Clay Whybark** *an assistant professor of operations management , University of North Carolina, Chapel Hill, USA **the Macon Patton Professor of Business , University of North Carolina, Chapel Hill, USA About Disassembly Analysis Robotics and Computer-integration Manufacturing, Volume 15, 1999, Pages 191-200 Ehud Kroll, Brad S. Carver Department of Mechanical and Aerospace Engineering, University of Missouri-Columbia/Kansas City, MO 64110, USA MAI Lab

  3. About Manufacturing Remanufacturing: The next great opportunity for boosting US productivity Business Horizons 46 (2003) 41-46 Ron Giuntini, Kevin Gaudette Executive Director, OEM Product-Services Institute, Lewisburg, Pennsylvania PhD Candidate in Operations and Decision Technologies, Kelley School of Business, Indiana University, Bloomington From Garbage to Goods: Successful Remanufacturing Systems and Skills Business Horizons, 43 (2000), 55-64 Geraldo Ferrer*, D. Clay Whybark** *an assistant professor of operations management , University of North Carolina, Chapel Hill, USA **the Macon Patton Professor of Business , University of North Carolina, Chapel Hill, USA OEM: Original Equipment manufacturer

  4. 목차 1. Remanufacturing이란? 2. 왜 Remanufacturing이 중요한가? 3. Remanufacturing 산업 현황 4. Remanufacturing의 Benefits 5. Remanufacturing의 걸림돌과 극복 방안 MAI Lab

  5. 1. Remanufacturing이란? • Three major recovery approaches • Recycling • 폐자재의 1차 분리에 의한 자원선별 • 예) 신문용지, 고철, …. • Recovery • 제품의 분해에 의한 폐기물과 재활용품 분리. • 예) 자동차 차체분리. 액상류 폐기 • Remanufacturing • 부가가치 창출 • 예) 자동차 폐 플라스틱을 고부가가치의 제품 생산. More retrieved Higher value-added MAI Lab

  6. What does it mean in industry to be productive? • Productivity: Output/input • More productive? “doing more with less” • Two primary input: labor and materials • Labor productivity • 이미 산업에서 연구와 적용이 많이 이루어짐. • 지난 50년간 300%의 생산성 향상은 주로 노동 생산성에 기인함. • Material productivity • A much newer concept • Material substitution & Recycling : 자재투입 감소. 기능 향상 • 하지만 Capital goods나 자동차산업, 국방부문에 국한되어 있다. • Process, design: the largest untapped resource for productivity improvement 2. 왜 Remanufacturing이 중요한가? • 수동적 측면 • Environmental issues • Resource consumption • 환경 규제. 기업 이미지. • 능동적인 측면 • Golden opportunity • 산업 생산성 향상 Remanufacturing MAI Lab

  7. 3. Remanufacturing 산업 현황 Source: Robert T.Lund, 1996, MAI Lab

  8. Source: OPI (OEM Product-Service Institute), 2003. DOD: Department of Defense MAI Lab HVAC: heating, ventilating, and air conditioning

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  11. 4. Remanufacturing의 Benefits • Business enterprises • 새로운 사업영역 • 생산성 향상 • Workforce • 고용 창출 • Retired and laid-off factory workers would be in high demand • Consumer • 낮은 가격(신제품 30~40%)에 비슷한 성능의 제품구매 • 선택의 폭 확대 • Society • 신제품에 비해 40~65% delivery costs, 15% 에너지 소비 • 원자재 재활용으로 자원 고갈 지연 • 환경오염 감소 MAI Lab

  12. 5. Remanufacturing의 걸림돌 및 해결책 MAI Lab

  13. About Disassembly Analysis Disassembly analysis through time estimation and other metrics Robotics and Computer-integration Manufacturing, Volume 15, 1999, Pages 191-200 Ehud Kroll, Brad S. Carver Department of Mechanical and Aerospace Engineering, University of Missouri-Columbia/Kansas City, MO 64110, USA

  14. 목차 1. Introduction 2. Related work 3. Manufacturability metrics 4. Disassembly time estimation 5. Disassembly analysis tool 6. Electric drill disassembly evaluation example 7. Other disassemblability measures 8. Conclusion MAI Lab

  15. 1. Introduction • Pressure to recycle • 환경에 대한 인식 증대, 규제 강화, 경제성 측면 • 위험물질 제거, 재사용부품의 회수, 재활용을 방안에 대한 요구 강화 • 제품 디자인에서 recyclability에 대한 고려가 필요하다. • 지금까지의 연구는 Material 속성 자체에만 치우침 • Process, design 의 중요성: cost of handling, sorting, disassembly • This paper • DFD (design for disassembly) evaluation metrics • A method for estimating disassembly time • Identify weaknesses in the design and improve it accordingly MAI Lab

  16. 2. Related work • DFD (design for disassembly) evaluation metrics • Design new products to make their disassembly for recycling easier • Concurrent engineering: function + manufacture + assembly + other life-aspect (the cost of handling, sorting and disassembly) • DFD vs. DFA (Design for assembly) • In fact many product which were designed for assembly are very difficult to take apart MAI Lab

  17. University of Rhode Island(1993) • Metrics to evaluate product serviceability in recycling • Time and cost estimation • Navin-Chandra(1994) • A computer-aided recovery analysis • Costs of recycling a product with the corresponding environmental and economic gains • Lee, B.H(1997) • Analyzing the cost drivers in product recycling. • The time required for separation of parts is identified as a key contributor to the overall cost of recycling. • Clumping” design strategy: collections of parts and subassemblies that share common characteristics • Gadh and his student(1997) • Design recommendations based on disassembly analysis MAI Lab

  18. Kalyan-Sheshu and Bras(1997) • Metrics to measure the remanufacturability of designs. • Boothroyd and Dewhurst(1987) • Assessing the ease or difficulty of various manufacturing processing • Hitachi • a 0~100 score assigned to each part based on its ease of assembly MAI Lab

  19. 3. Manufacturability metrics • DFM (design for manufacturability) metrics • Measure of the effort required to manufacture the product • Include disassembly as well as other life-cycle concerns • Absolute metrics • metric, such as time or cost estimates, • 설계 변경에 따른 대안들의 평가 • 단점: 비교 대상이 없다면 비교평가 불가. • Relative metrics • Metrics are normalized with respect to some ideal situation 예) 해체시간 15분, Good or bad? 그 자체가 얼마나 좋은지 알 수 없음. Boothroyd and Dewhurst(1989) 3 x (Theoretical min. num. of parts) Assembly Design Efficiency = Estimated total assembly time 3 : the theoretical minimum time required to handle and insert that is perfectly suited for assembly 예)Rating 20%, Good or bad? 100%가 Ideal이므로 개선의 여지가 있다. MAI Lab

  20. Relative metrics의 활용 • Scenario I: Design assistance. • 해체 작업시간 예측. • 해체 작업에 대한 평가 및 개선. • Scenario II: DFD regulatory standards. • German & Blue Angel eco-label, European CARE &VISION 2000, EPA's & Energy Star programs, ISO 14000 series • 환경 규제를 수치로 명시할 수 있다. 예) DFD rate 40% 이상 MAI Lab

  21. 4. Disassembly time estimation • Four different sources of difficulty in performing dismantling tasks • Accessibility: a measure of the ease with which a part can be reached by the tool or hand. • Positioning: the degree of precision required to place the tool or hand. • Force: a measure of the effort required to do the task. • Base time: the time required to do the basic task movements without difficulty. • All these aspects of disassembly difficulty have the meaning of time: a task that poses accessibility problems, requires precise tool positioning, or calls for exerting large forces, would take longer to complete. • Difficulty scores: on a scale of 1 (easiest) to 10 (most difficult). • MOST work-measurement system • A predetermined time system which provides standard time data for the performance of sequences of basic motions. • If a disassembly task is divided into a series of elementary movements, the system can predict the time required for a worker with average skill MAI Lab

  22. Difficulty scores • ① Identify and define standard disassembly activities or tasks. • Standard tasks were determined through observation of manual disassembly experiments. • Key steps in the performance of each task were noted and analyzed with the MOST system. • The quickest and most efficient method for performing a task under average conditions, as determined from the MOST analysis, was designated the standard task model. • ②The effects of various disassembly conditions were investigated. • Factors: obstructions, handling difficulties, resistance, .. • Assessed by assigning appropriate MOST parameter indices. • More complicated disassembly, higher parameter indices, more increased overall task performance time. • The sequence parameters in each task model were then categorized according to the aspect of task performance they measured: accessibility, positioning, force, and base time. • A fifth category, special, was added to account for various non-standard effects. MAI Lab

  23. ③Create the difficulty scale of 1~10 • Difficulty of 1 : “ideal task”, basic hand motions required to pick up, move, and place an object. • Difficulty of 10: the movements of the hand and forearm to twist a screwdriver against heavy resistance. • The difficulty scores for each task  Estimates of task performance time MAI Lab

  24. 5. Disassembly analysis tool • A spread sheet-like chart Total= (Column 5) X (column 12) MAI Lab

  25. 6. Electric drill disassembly evaluation example MAI Lab

  26. 2 1 1 2 1 3 1 1 WE 3 PB 21 7 • Part 3 disassembly • Disassembling the upper housing (part 3) required the use of a prybar to wedge it from its snug fit by repeating the operation 3 times. • Light pressure had to be applied to insert the tip of the tool into the easily-accessible grooves, followed by overcoming light resistance to the actual prying. MAI Lab

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  28. the least difficulty : a score of 1 in each of the five categories, for a total score of 5 7. Other disassemblability measures • Simple measures • The actual number of parts which were disassembled • The number of parts disassembly tasks • The number of different tools used • The number of tool manipulations • The number of hand manipulations • Disassembly effectiveness This effectiveness rating fails. Why? Difference between disassembly and assembly: While every part is assembled separately, several parts may be removed by one disassembly operation. 예) 나사를 일단 풀고 덮개를 뒤집으면 한번에 4개 나사가 떨어짐 MAI Lab

  29. 8. Conclusion • The disassembly evaluation method • Intended to help designers identify weaknesses in the design from the disassembly viewpoint. • The other use emphasized in this paper is as a time estimation tool. Time estimates provide a powerful measure of ease of disassembly when used for comparing alternative designs of the same product. • Relative disassemblability metrics MAI Lab

  30. 전체 결론 • Good Topic • 환경 문제 + 산업공학적 접근 • Paper reading • 관련 논문 정리. • 현대자동차 프로젝트와의 연계 MAI Lab

  31. DFX (Design for X) • X : Manufacturing, Cost, Quality , Product, Assembly 1/6 MAI Lab

  32. DFQ (Design For Quality) • 제품을 개발함에 있어서 요구되는 품질을 체계적으로 전개해 나감으로써 제품의 신뢰성 향상 및 품질 보증을 통하여 고객의 만족도를 향상시킨다. QFD: Quality Function Deployment 품질 기능 전개 FMEA: Failure Mode and Effects Analysis. DFMEA (design), PFMEA (process) FTA: fault tree analysis 결함수분석법 QC: Quality Control. 품질관리 DR: Development of Reliability 2/6 MAI Lab

  33. DFP / A (Design For Product, Assembly) VE: Value Engineering 가치공학 VR: Value ? DFA: Design for Assembly 조립을 고려한 설계 3/6 MAI Lab

  34. DFM (Design For Manufacturability) • 제품 생산 면에 있어서의 제반 문제점을 검토 개선하고, 최적 생산관리체제를 구축하므로 종합 생산성을 향상시킨다. TPM: Total Productive Maintenance IE: Investment Engineering JIT: Just In Time 4/6 MAI Lab

  35. DFC (Design For Cost) • 원가 관리를 통하여 제품의 COST를 MINMUM화 해 나간다. 5/6 MAI Lab

  36. DFM 절차 Estimate the manufacturing costs Reduce the costs of components Reduce the costs of assembly Reduce the costs of supporting production Consider the impact of DFM decisions on other factors Recompute the Manufacturing Costs Good Enough? NO YES Acceptable Design 6/6 MAI Lab

  37. MTM & MOST • MTM-1 (Methods-Time Measurement) • In 1948, MTM-1 was published. H.B. Maynard, G.J. Stegemerten, J.L. Schwab. • Time values for the fundamental motions: reach, move, turn, grasp, position, disengage, release • MTM-2, 3, C, M, V • MOST (Maynard Operation Sequence Technique) • An outgrowth of MTM • 1967년 스웨덴의 Saab-Scani에서 Kjell B.Zandin에 의해 개발 • H.B. Maynard and Company is currently marketing MOST • The company states that analysts can establish MOST standards at least five times faster than MTM-1 standards, with little if any sacrifice in accuracy. • Larger blocks of fundamental motions that MTM-3 1/2 MAI Lab

  38. MTM & MOST • Three standard sequence models form the basis of the MOST system: ① The general move sequence for moving unconstrained objects through the air ② The controlled move sequence for moving objects constrained in some way, ③ The tool use sequence for use of hand tools.  An activity (e.g., unscrewing) is analyzed as a series of the standard sequence models. • The subactivities, or sequence parameters, • Letter: make up each MOST sequence are represented by letters. A(손동작), B… • Numerical index: the performance time of the subactivity. 0, 1, … • TMU (time measurement units, 1 TMU =0.036 s) for each sequence is calculated by summing the indices of all the parameters in the model and multiplying by 10. • Example “basic remove task” • A1 B0 G1 A1 B0 P1 A1 • The hand is moved to a loose part within reach (A1) • With no body movement (B0) to gain control over this light, easily grasped part (G1). • The part is next moved to a storage bin within reach (A1) • Without body movement(B0) • And placed in the bin (P1) before the hands are returned to the assembly (A1). • The corresponding performance time is 50 TMU or 1.8 s. 2/2 MAI Lab

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