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Is the Automotive Industry Using Design-For-Assembly Anymore?

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Is the Automotive Industry Using Design-For-Assembly Anymore? MIKAEL EHRS Is the Automotive Industry Using Design-for-Assembly Anymore? A Statistical Analysis of Repair Data ACTA WASAENSIA NO 273 ________________________________ INDUSTRIAL MANAGEMENT 27 UNIVERSITAS WASAENSIS 2012 Reviewers Dr. Kim Hua Tan Nottingham University Business School Jubilee Campus Wollaton Road Nottingham NG8 1BB UK Associate professor Antti Pukkinen Tampere University of Technology Department of Production Engineering P.O. Box 589 FI–33101 Tampere Finland III Julkaisija Julkaisupäivämäärä Vaasan yliopisto Marraskuu 2012 Tekijä(t) Julkaisun tyyppi Mikael Ehrs Monografia Julkaisusarjan nimi, osan numero Acta Wasaensia, 273 Yhteystiedot ISBN Vaasan yliopisto 978–952–476–422–3 Teknillinen tiedekunta ISSN Tuotantotalouden yksikkö 0355–2667, 1456–3738 PL 700 Sivumäärä Kieli 65101 Vaasa 281 Englanti Julkaisun nimike Käyttääkö autoteollisuus vielä Design-for-Assembly -menetelmää? Tilastollinen analyysi kunnossapitodatasta Tiivistelmä Työn tarkoitus: Lähitulevaisuudessa uudet autonvalmistajat Kiinasta ja Intiasta haastavat vanhempien teollisuusmaiden autonvalmistajat. Innovatiivisten suunnit- telumenetelmien käyttö voisi kuitenkin muodostaa vahvan kilpailuedun haastee- seen vastaamisessa. Metodologia: Tiettyjen korjausmääritelmien mukaan korjausaikadatasta voidaan ekstrapoloida Design-for-Assembly:n (DFA eli kokoonpano-orientoitunut suun- nittelu) käyttö. Kirjallisuuskatsauksen ja autoteollisuuden asiantuntijahaastattelui- den avulla pystytään havaitsemaan positiivinen korrelaatio nopean kokoonpanon ja nopean purkamisen välillä. Tämä työ tutkii korjausaikadataa 20 vuoden aikajaksolla ja vertaa yli 300 sedan- mallin tietoja Aasiasta, Euroopasta ja USA:sta tilastollisesti tuotteittain ja yrityk- sittäin mm. ANOVA-analyysillä. Tutkimuksen tulokset: Keskimääräisen auton kokoonpanoaika on kasvamassa: autoteollisuus käyttää yleiskäyttöisiä moduuleja, jotka eivät seuraa käytettävissä olevan DFA-suunnittelun menetelmiä. Tämä osoittaa toimitusketjun globaalia luonnetta ja toimittajien kasvavaa tärkeyttä komponenttisuunnittelussa. Pohjois- amerikkalaiset mallit ovat yksinkertaisimpia koota. Tutkimuksen rajoitteet: Kysymystä positiivisesta DFA/DFD korrelaatiosta ei näy- tetty empiirisesti toteen. Tarkan korrelaation löytäminen vaatii lisää numeerista tutkimusta. Tutkimuksen vaikutukset: Autoteollisuuden laajamittainen moduulien käyttö vaatii tarvittavien kustannussäästöjen saavuttamiseksi toimittajilta valmiuksia DFA:n käyttöön. Amerikkalaisten autonvalmistajien osaaminen on tunnustettava; niiden mallien käyttö voi tarjota myös alihankintateollisuudelle kyvyn luoda kus- tannustehokkaampia moduuleja. Tutkimuksen kontribuutio: Aineistoon pohjautuvia tutkimuksia autoteollisuuden DFA-käytöstä (ja DFA:n/DFD:n korrelaatiosta) on tehty hyvin vähän. Tässä tut- kimuksessa on toteutettu kattava vertailu DFA:n käytöstä autoteollisuudessa tuo- temalleittain, vuosittain, tuotantoalueittain ja yrityksittäin. Asiasanat Design-for-Assembly, DFA, autoteollisuus, Design-for-Disassembly, DFD V Publisher Date of publication Vaasan yliopisto November 2012 Author(s) Type of publication Mikael Ehrs Monograph Name and number of series Acta Wasaensia, 273 Contact information ISBN University of Vaasa 978–952–476–422–3 Faculty of Technology ISSN Department of Production 0355–2667, 1456–3738 P.O. Box 700 Number Language FI–65101 Vaasa of pages Finland 281 English Title of publication Is the Automotive Industry Using Design-for-Assembly Anymore? A Statistical Analysis of Repair Data Abstract Purpose: Soon, the car companies of the older industrialized countries will be challenged by the car companies of China and India. However, innovative use of design practices could provide the compete advantage to return the challenge. Methodology: For certain definitions of repair, use of Design for Assembly and Disassembly can be extrapolated from repair data. From literature review and interviews with automotive experts, a certain degree of positive correlation be- tween ease of assembly and ease of disassembly can be found. This work explores repair data from 20 years and compares over 300 sedan mod- els from Asia, Europe and USA – by statistical ANOVA analysis and on product and individual company basis. Findings: The average car assembly time is growing: the average car uses uni- versal components that do not approximate available automotive DFA redesign examples. This indicates the global nature of the supply chain and the im- portance of suppliers to provide component design. North American models are the easiest to assemble. Research limitations: The question of positive DFA/DFD correlation is not em- pirically proven. Further numerical study seems necessary to establish exact cor- relation. Practical implications: The automotive industry's use of modularity dictates that suppliers must be the next generation of cost-efficient DFA users. The expertise of the American car companies must be recognized; they can provide the knowledge the supply industry needs to create leaner modules. Originality value: Very few quantitative studies on industry-wide DFA usage (and DFA/DFD correlation) currently exist. Furthermore, an up-to-date bench- mark on expertise in DFA is produced. Keywords Design-for-Assembly, DFA, automotive industry, Design-for-Disassembly, DFD VII ACKNOWLEDGEMENTS To begin with, I would like to express my immense gratitude towards my three mentors and teachers – professors Petri Helo, Tauno Kekäle and Josu Takala. They saw a potential and made that potential reach its fulfillment. They have pro- vided support, advice, opportunities and most importantly – have lead by exam- ple. And a fine example it has been. I would also like to thank my family for their constant support in my struggle towards education. When discussing with them, every problem easily produces several solutions and every day brings new opportunities of going forwards and upwards. Who could ever fall with such a brace to lean on? Also, a special thank-you to my sister, who contributed artistically to this work. I am much obliged! Vaasa 30.10.2012 Mikael Ehrs IX Contents ACKNOWLEDGEMENTS............................................................................. VII 1 INTRODUCTION ........................................................................................ 1 1.1 Objectives and Research Questions .................................................... 2 1.2 Research contribution and applications ............................................... 3 1.3 Structure of the study ......................................................................... 4 2 LEAN DESIGN AND DESIGN FOR ASSEMBLY ...................................... 6 2.1 Lean design and current product development methods ..................... 6 2.1.1 Concurrent engineering ...................................................... 7 2.1.2 Modularity and product platforms ...................................... 9 2.1.3 Design for X .................................................................... 12 2.2 Design for Assembly ........................................................................ 14 2.3 Historical Origin of DFA .................................................................. 16 2.4 Development Generations ................................................................ 18 2.4.1 First generation DFA........................................................ 19 2.4.2 Second generation DFA ................................................... 21 2.4.3 Third Generation of DFA ................................................. 30 2.5 Does DFA work?.............................................................................. 31 2.6 Is it used? ......................................................................................... 35 3 THE AUTOMOBILE INDUSTRY AND DFA ........................................... 42 3.1 A short background on the automobile industry and its situation today. ............................................................................................... 42 3.1.1 Early history .................................................................... 42 3.1.2 Situation before the 2008–2009 automotive industry crisis ................................................................................ 49 3.1.3 Situation during the 2008–2009 automotive crisis ............ 57 3.2 The Automotive Assembly Process Explained .................................. 69 3.3 Why is DFA relevant to the auto industry? ....................................... 74 4 THE CONNECTION BETWEEN ASSEMBLY AND REPAIR ................ 84 4.1 Design for Assembly guidelines ....................................................... 84 4.2 Design for Maintainability guidelines ............................................... 86 4.3 Design for Disassembly .................................................................... 89 4.4 Connecting DFA and DFD – Evidence from academic research ....... 93 4.5 Connecting DFA and DFD – Interview results.................................. 94 5 METHODS AND DATA COLLECTION ................................................. 100 5.1 Selecting Sources of Data ............................................................... 102 5.2 Car Model Selection ....................................................................... 106 5.3 Car Model Selection ....................................................................... 112 5.4 Sub-Assembly Selection ................................................................. 116 5.5 Data collection and limitations of the data .....................................
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