First time right - Prokon

ProKon

ProKon

Produktionsgerechte Konstruktion

(Production-Oriented Design)

First Step in First Time Right

Presented at – MTM Conference Turkey May, 2014

ProKon Analytical Method

3 A/AA © MTM-Institut 2 Manual page

The term ProKon is an acronym for the German words

Produktionsgerechte Konstruktion (Production-Oriented Design)

The ProKon method is a comprehensive tool for

improving the manufacturing process, during

the design phase of product development.

ProKon Development of the Market Place


Shorter product life cycles

Increasing number of variants

Increasing frequency of product innovations

Shorter development times

Increasingly complex development tasks

ProKon Demands on Product Development


Greater flexibility

Quick reaction to changes in the market place

Consideration of all cost-relevant factors, at an early stage of development

ProKon Problem with Positioning a Platform


• Large batch sizes • Ideal product mix • Reduced development expense • Reduced material costs • Short learning curve

Where is the company‘s optimum?

Customer Requirements Tailored Solution

Company Targets Standard Solution

* Prof. Dr. Ing. W. Engeln

0 % Individuality of the solution 100 %

• Single piece order • Complex product mix • Increased development expense • Increased material costs • Longer learning curve

ProKon Early Answers to Late Questions


Time

Costs

Costs of implementing

a change

Opportunities for avoiding or

reducing costs

Concept Services Design Prototype Purchasing Department

Production/ Assembly

Sales

ProKon Optimization Potential


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Total costs Assembly-oriented

product design

New production

technologies

Work system and

work process

design

CIP measures Remaining costs

100%

20 - 30%

5%

10 - 20%

15%

Op

tim

iza

tio

n p

ote

nti

al in

%

ProKon MTM in the overall production cycle


MTM Analysis Planning Production analysis

testing

optimization

quantification

familiarization

Know-how transfer

Product Development

Process Development

Production and Improvement

SOP (Start of Production)

inspection and evaluation of

ease of assembly

process capability

quality objectives

product optimization

work organization

work design

work methods

production times

clocking

possible production optimization

calculation of reference data/planning standards

MTM Process Planning Methods and tools

ProKon

continuous improvement

Ergonomics - EAWS

ProKon Definition


ProKon is an MTM-based method for analyzing and evaluating design solutions with respect to their suitability for assembly. ProKon supports the systematic identification of possible improvements in design solutions and the quantification of the effect these solutions have on productivity.

ProKon

ProKon Ease of Assembly


Influencing factors affecting the assembly are

defined as analyzing criteria, represented by

Basic Value

Assembly Interferences

For each of these criteria, a numerical value –

a ProKon Unit (PU) – was defined.

ProKon Advantages of the Application of ProKon


Identification of assembly interferences at the earliest possible point of time

Quantification of the identified assembly interferences

Target-oriented reduction of the identified assembly interferences

Creation of valuable basic information for further process planning

Promotion of cross-functional communication

Avoidance of subsequent product changes

ProKon Advantages of the Methodology


ProKon offers high analyzing speed

ProKon is easy to learn

ProKon enhances the designer’s creativity, thus supporting the creative process

ProKon

Partial project:

Number of parts:

∑ Frequency:

ProKon Units: 40 55 10 100 10 15 40 15 35 15 20 10 15 20 100 50 150 300 40

∑ Total value:

ProKon Analysis SheetNumber of partial project:

User:

Date:

Sub-assembly:

Number

of Tools

Used

Basic Value Assembly Interferences

Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

∑ ProKon Units:

Assembly Steps ≤ 8 kg > 8 kg 2 3 >3

Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per

axis (x, y, z)

Adjust-

ment/

Check

Processes

visi-

bilityspace P1 P2 P3

ProKon Analysis Sheet


Question on design Is it possible that existing components take on additional functions and, thus, reduce the number of components?

Assembly situation

Chronological order

of assembly

ProKon Value Added and Waste


The ProKon analysis DOES NOT describe the actual assembly process.

Verschwendung

Activities analyzed with ProKon

ASSEMBLY

Value-adding activities

Non value-adding activities

Waste

• Position • Fasten • Engage • Glue together

• Distances • Waste disposal • Reading an order • Material transport

• Adjustment • Readjustment • Restrictions

ProKon Targets of Application


Identifying and assessing weak points in the design that cause assembly interferences

Giving new impetus to the target-oriented optimization of the product design

Designing ergonomically favorable solutions

Standardizing processes (quality improvement) by establishing a uniform platform and creating modules, which can be used again

ProKon Steps in Implementing Projects


Industrial Engineering, planning, competitive analysis, service

ProKon team: Design/development, planning, IE/MTM, supplier member of specialist department (if required)

Design/development, planning, IE/MTM, quality assurance, purchasing department, supplier member of specialist department (if required)

Yes

Create and evaluate design alternatives

Design/development, planning

Select component/sub-assembly

Supply prototype/drawing...

Assess current design

Realize optimized design

No Are the

alternatives achievable? (Process reliability,

costs, quality)

ProKon How to Proceed during the Analysis


• In the ProKon Analysis Sheet, the assembly steps are described in the vertical and the specific assembly interferences in the horizontal direction.

• Frequencies are entered on the corresponding lines.

• The frequencies per column are summed (∑ Frequency) and multiplied by the corresponding ProKon Units …

• … yielding the individual value of ProKon Units per column (∑ Total).

• The individual values of all columns are summed to the total value (∑ ProKon Units)

The smaller the total value, the greater the suitability for manual assembly.

ProKon Steps in Analyzing the Present Design


Present Design

Steps

1 Name the components or sub-assemblies

2 Define the assembly steps

3 Define the assembly position (x, y, z)

4 Evaluate the components or sub-assemblies with the help of the ProKon analysis sheet

ProKon Knowledge Gained


The matrix enables the analyst to make statements regarding the components or sub-assemblies and the occurring:

Type of assembly interference and

The frequency or combination of assembly interferences

The matrix yields a total value for the complete assembly.

Every assembly interference indicates design features that have to be reviewed for possible

improvements.

ProKon Steps in Analyzing the Proposed Design


Proposed Design

Steps

5 Question the present design

6 Optimize the design through alternative solutions

7 Reassess the modified design using the ProKon analysis sheet

ProKon Principles on Changing the Design


Simplification of components

Simplify the geometry of components

Geometry that allows for only one positioning direction

Component that can be assembled in only one position (avoiding assembly errors and associated rework)



Support by positioning aids and available space

Positioning/centering aids, such as bevels, pivots, reliefs/marks

Positioning clearance/accessibility (ergonomics)



Simplification of directions/positioning axes

Reduce the number of positioning locations

Standardize positioning/fastening directions (for example, feeding from above)

Design special positioning locations to enable easier assembly

(for example, door hinges of different lengths)



Standardization of components

Reduce the number of components that require

different assembly methods

Standardization of fastening elements and torques

Reduce the number of tool changes, tool costs



Integration of components/functional integration

Reduce the number of components to be assembled

Integrate, for example, a fastening element in the component

ProKon Basic Value


Basic Value describes the ideal assembly of a component or sub-assembly without considering any assembly interferences.

Number of parts: Number

of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-

bilityspace P1 P2 P3Assembly Steps ≤ 8 kg > 8 kg 2 3 >3

Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per

axis (x, y, z)

Basic Value

ProKon Main Dimension > 300×300 mm


Main Dimension > 300 x 300 mm refers to the dimensions of a com-ponent or sub-assembly that essentially determine its outer geometry.

Number of parts:


Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per

axis (x, y, z)

Number

of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Main Dimension >300 × 300 mm

ProKon


of tools

used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Process

visi-

bilityspace P1 P2 P3Assembly Steps ≤ 8 kg > 8 kg 2 3 >3

Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per

axis (x, y, z)

Dimension of Part > 800 mm


Dimension of Part > 800 mm describes a component or sub-assembly with at least one dimension > 800 mm.

If the main dimensions of a component are > 300 x 300 mm and one dimension is > 800 mm, then only the Assembly Interference Dimension of Part > 800 mm is evaluated.

Dimension of Part > 800 mm

Note

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per

axis (x, y, z)Assembly Steps ≤ 8 kg > 8 kg 2 3 >3

Number of Positioning Locations


two positioning locations several positioning locations one positioning location

Number of Positioning Locations refers to the number of locations in which a component or sub-assembly has to be positioned to reach its final position.

Number of Positioning Locations

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per


Restriction due to Visibility/Space


Restriction refers to an assembly process in which obstructions may occur, due to poor visibility or insufficient space.

Restriction due to visibility/space

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per


Improper Fitting Possible


Layout

Improper Fitting Possible refers to an assembly process in which it is possible to assemble a component or sub-assembly in more than one way. One or more of the possible fitting positions may be wrong (Poka Yoke).

Improper Fitting Possible

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per


Holding in Place Required


Holding in Place Required refers to an assembly process in which a component or sub-assembly is not in a stable (final) position after initial positioning.

Holding in Place Required

ProKon Example on Holding in Place Required


1. Place base plate in stable position

2. Lay washer on base plate and hold it in place

3. Place lock washer on washer and hold it in place

4. Position bolt through lock washer and washer and hold it in place

5. Engage thread

6. Turn on and tighten bolt

Base plate

Bolt

Lock washer

Washer

Example: Assemble bolt with lock washer and washer

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per


Readjustment while Positioning


On the X-axis the position is defined by stops. On the Y-axis there is no stop, so readjustment is necessary.

Readjustment while Positioning refers to additional corrective motions that are required to place the component in its final position, following its initial positioning.

Readjustment while Positioning

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per


Without Positioning Aids


Without Positioning Aids refers to an assembly process in which neither the component or sub-assembly, nor the positioning location is equipped with positioning aids, such as stops, guides, etc.

without positioning aid

with positioning aid

Without Positioning Aids

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per


Change in Positioning/Fastening Dir.


Change in Positioning Direction becomes necessary, within a positioning process, if a component or sub-assembly has to be positioned in more than one direction along a defined positioning axis.

Change in Fastening Direction exists if a component or sub-assembly has to be fastened in more than one fastening axis/direction along at the destination.

Change in Positioning/ Fastening Direction

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per


Adjustment/Check


Adjustment/Check refers to design-caused processes that must be performed prior to completing subsequent activities.

Adjustment/ Check

ProKon


of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per


Processes


All activities that are not performed for the purpose of positioning components are called Processes.

Processes

ProKon

Number of parts:


Adjust-

ment/

Check

Processes

visi-


Readjust-

ment

while

Position-

ing

Without

Position-

ing Aids

Change in

Positioning/

Fastening

Direction per

axis (x, y, z)

Number

of Tools

Used


Weight, incl.

1st positioning

location

Main

Dimension

>300×300

mm

Dimen-

sion

of Part

> 800

mm

Number of

Positioning

Locations

Restriction

due to Improper

Fitting

Possible

Holding

in Place

Required

Number of Tools Used


Number of Tools Used indicates the number of tools required to perform an assembly. (For example, changing a socket would require an entry in this column.)

Number of Tools Used

ProKon Time-Influencing Factors


ProKon

Units

The primary sector describes those influencing factors in the ProKon Analysis Sheet (ProKon Units) that affect the positioning location itself and thus, directly impact the assembly time.

The secondary sector describes influencing factors that affect such things as parts supply and layout design at and around the work station and thus, indirectly impact the assembly time. Overall Work System

ProKon Possibilities for Time Data Determination

39/40 A/AA © MTM-Institut 41 Manual page

Creation of an MTM Planning Analysis based on the parameters defined for the future work system to be established for the new product

Reference to existing MTM data previously developed for a sufficiently comparable product, while adjusting details, where required

Comparison with a reference product, while estimating significant deviations

The time value established is utilized in the calculation of the factor, as described below:

∑ ProKon Units × Factor = Assembly Time (minutes)

Time value from analysis (real assembly time) in min

∑ ProKon Units = Factor

ProKon Example: Collar Band


Assembly Steps • Place anchor into pre-drilled bore hole

• Drive in anchor

• Place collar band on anchor

• Place screw and turn it in

Present Design



Assembly Steps • Place collar band

• Place nail anchor and drive it in with hammer and hand tool

Proposed Design – Variant A



Description Number of

components ProKon Units %

Present Design 3 385 100

Proposed Design - Variant A 2 255 66

Proposed Design - Variant B 1 135 35

Assembly Steps • Place collar band with integrated anchor into pre-drilled bore hole and press it in

Proposed Design – Variant B

ProKon Example: Car Headlight


Assembly Steps •Place headlight housing

•Place self-tapping screw to z-axis and turn on

•Place self-tapping screw to y-axis and turn on

•Place washer and nut to ×-axis and turn on

Tapping screw to z-axis

Tapping screw to y-axis Washer and

nut to x-axis

Present Design

ProKon Example: Car Headlight


Assembly Steps Place headlight housing on locking pins

Place self-tapping screw and turn on

Description Number of

components ProKon Units %

Present design 5 835 100

Proposed design 2 345 41

Circular rubber sealing

Locking pins to x-axis

Tapping screw to x-axis

Proposed Design

ProKon Project AX: Sun Visor Retainer


Inside bracket Cover cap

2 self-tapping screws

Assembly Steps

• Get bracket

• Position to 2 bore holes in front center of inner roof lining

• Fasten bracket with 2 self-tapping screws

• Get cover cap

• Engage cover cap in bracket

Present Design

ProKon Project AX: Sun Visor


1st Engage (bracket)

2nd Engage (cover cap)

Assembly steps

• Get bracket

• Position to front center of roof lining

• Engage bracket (1st engage)

• Get cover cap (fasten to bracket by film hinge)

• Engage (2nd engage)

Proposed Design

ProKon Project AX: Sun Visor – Result


State of Design Components Production Time

Present Design

1 bracket

2 tapping screws

1 cover cap

0.50 min per retainer

Proposed Design

1 bracket with integrated

fastening elements

1 cover cap

0.25 min per retainer

Delta per retainer 0.25 min per retainer

2 retainers are assembled to every car. This results in a reduction in production time of 0.50 min per car. In addition, 4 tapping screws, with a material value of € 0.08, can be omitted.

ProKon Success Factors


Customer Orientation • Company focuses on its customers‘ wishes.

Added Value • All non value-adding activities are to be avoided.

Standardization • Mastering the diversity of types and models through standardization.

Many variants with few variables (using identical components and sub-assemblies)

• Formalization of processes with clearly defined interfaces (no double work on the system boundaries)

Thinking and Planning Ahead • Acting instead of reacting, i.e., it’s better to avoid problems than to

eliminate them.

ProKon Success Factors


Small, Controllable Steps • Feedback from one step controls the following step. Consequently, if

errors occur, they will not be as severe and can easily be corrected.

Elimination of Errors at the Root of the Problem • To prevent the repetition of an error, its cause, not its effect, has to

be eliminated.

Personal Responsibility • The responsibility for any job lies with the person performing this job,

i.e., staff members become co-entrepreneurs.

Team • All for one and one for all, i.e., it’s the team’s results that counts.

Continuous Improvement • Continuous improvement of all performances at any time, i.e., the

journey is the reward.