TABLE OF CONTENTS

ACKNOWLEDGEMENT ............................................................................................ i

ABSTRACT................................................................................................................. ii

LIST OF TABLES ....................................................................................................... v

LIST OF FIGURES .................................................................................................... vi

ABBREVIATIONS .................................................................................................. viii

NOTATIONS.............................................................................................................. ix

CHAPTER 1 INTRODUCTION AND LITERATURE SURVEY

1.1 Introduction ...................................................................................................... 1

1.2 Overview of automobile manufacturing process ............................................. 2

1.2.1 Press and Body Shop ....................................................................................... 3

1.2.2 Paint Shop ........................................................................................................ 4

1.2.3 Assembly Shop ................................................................................................ 5

1.3 Overview of Material Handling Method.......................................................... 6

1.3.1 Continuous Supply and Batch Feeding Method .............................................. 6

1.3.2 Kitting Part Feeding Method ........................................................................... 7

1.3.3 Sequential Part Feeding Method ...................................................................... 8

1.4 Problem Definition........................................................................................... 9

1.4.1 Limitation of the Present Part Feeding Method ............................................. 10

1.5 Literature survey ............................................................................................ 11

1.6 Motivation ...................................................................................................... 20

1.7 Objective and Scope of Work ........................................................................ 21

1.8 Methodology .................................................................................................. 21

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1.8.1 Working Structure and Methods used............................................................ 21

1.9 Outline of the Thesis ...................................................................................... 22

CHAPTER 2 DESIGN AND DEVELOPMENT OF PART FEEDING

SYSTEM PROTOTYPE

2.1 Introduction .................................................................................................... 23

2.2 Design Features of Prototype Model ............................................................ 23

2.3 Sensor and signal processing ......................................................................... 25

2.3.1 Pyro electric Infra Red Sensor and Its Working Principle ............................. 25

2.3.2 Interfacing of Pyro electric Infra Red Sensor (PIR) With Arduino ............... 26

2.3.3 Signal Processing of PIR Sensor ................................................................... 27

2.3.4 Laser Trip Wire Beam Sensor and its Working Principle ............................. 28

2.3.5 Interfacing of Trip Wire Beam Sensor (LDR) with Arduino ........................ 28

2.3.6 Interfacing of Radio-frequency Identification with Arduino ......................... 29

2.3.7 Signal processing of LDR sensor................................................................... 30

2.3.8 Load cell and its working Principle ............................................................... 31

2.3.9 Selection of Load cell .................................................................................... 31

2.3.10 Interfacing of Load Cell is with Arduino ....................................................... 33

2.3.11 Signal Processing of the Load Cell ................................................................ 34

2.3.12 Microcontroller Selection .............................................................................. 34

2.4 Development of Mechanical Structure .......................................................... 35

2.5 Programming Algorithm ................................................................................ 36

2.5.1 User Authentication Algorithm...................................................................... 38

2.5.2 Part Quantity Management Algorithm........................................................... 39

2.5.3 Part Picking Error Detection Algorithm ........................................................ 40

2.5.4 Part Assembly Quality Tracking Algorithm .................................................. 41

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2.6 Summary ........................................................................................................ 42

CHAPTER 3 EXPERIMENTAL INVESTIGATION OF PART FEEDING

SYSTEM PROTOTYPE

3.1 Introduction .................................................................................................... 43

3.2 Purpose of Load Cell Calibration .................................................................. 43

3.3 Description of the Calibration Setup.............................................................. 44

3.4 Method of Load Cell Calibration ................................................................... 44

3.4.1 Determination of the Resolution and Weight Boundary................................ 45

3.4.2 Determination of the Stuffing Quantity ......................................................... 46

3.5 Load Cell Calibration Procedure ................................................................... 46

3.6 Load cell Calibration Data ............................................................................. 47

3.7 Load cell Calibration Inference ..................................................................... 49

3.8 Light Dependent Resistor (LDR) Calibration ................................................ 50

3.9 Description of the LDR Calibration Setup..................................................... 50

3.10 Purpose and Method of LDR Calibration ...................................................... 51

3.11 Apparatus used for LDR Calibration ............................................................. 52

3.12 LDR Calibration Procedure ........................................................................... 53

3.13 LDR Calibration Data .................................................................................... 53

3.13 LDR Calibration Inference ............................................................................ 59

3.13 Pyro electric Infra Red (PIR) Sensor Calibration .......................................... 60

3.17 Summary ........................................................................................................ 61

CHAPTER 4 RESULT AND DISCUSSION

4.1 Introduction .................................................................................................... 62

4.2 Feeder Man-Hour Efficiency Improvement................................................... 62

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4.3 Specification Error Reduction........................................................................ 64

4.4 Human Error Tree for Material Handling Process ......................................... 67

4.5 Summary ........................................................................................................ 69

CHAPTER 4 CONCLUSIONS AND SCOPE FOR FUTURE WORK

5.1 Introduction .................................................................................................... 69

5.2 Conclusions .................................................................................................... 69

5.3 Scope for Future Work................................................................................... 70

REFERENCES .......................................................................................................... 71

APPENDIX 1 ARDUINO PROGRAM ................................................................... 74

APPENDIX 2 MATLAB PROGRAM ..................................................................... 86

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LIST OF TABLES

1.1 Present Part Feeding Method in Hyundai production Unit ..............................11

2.1 Design Features and Parts of Prototype Model................................................24

2.2 Laser Beam Emitter Specification ...................................................................28

2.3 Load Cell Types ...............................................................................................32

2.4 Load Cell CZL 601 Specification ....................................................................32

3.2 Variation of Light in Testing Environment .....................................................53

3.3 Laser Trip Beam and LDR Setup (A) Calibration Data ..................................54

3.4 Laser Trip Beam and LDR Setup (A) Calibration Result ................................55

3.5 Laser Trip Beam and LDR Setup (B) Calibration Data ...................................55

3.6 Laser Trip Beam and LDR Setup (B) Calibration Result ................................56

3.7 Laser Trip Beam and LDR Setup (C) Calibration Data ...................................57

3.8 Laser Trip Beam and LDR Setup (C) Calibration Result ................................57

3.9 Laser Trip Beam and LDR Setup (D) Calibration Data ..................................58

3.10 Laser Trip Beam and LDR Setup (D) Calibration Result ................................59

LIST OF FIGURES

1.1 Summar of Manufacturing Process ....................................................................2

1.2 Major Operations of Press Shop ........................................................................3

1.3 Major Welding and Joining Operations of the Body Shop ................................4

1.4 Major Painting Process of Paint Shop ...............................................................4

1.5 Work Station Layout of Assembly Shop ...........................................................5

1.6 Production Models of Hyundai Motors India ...................................................6

1.7 Continuous Batch Part Feeding Method ............................................................7

1.8 Kit Part Feeding Method....................................................................................8

1.9 Sequence Feeding Method .................................................................................9

1.10 Month Wise Spec Error and Part Shortage Error Trend ..................................10

1.11 Categorization of Material Supply System .....................................................12

1.11 The Working Structure and Strategy Followed During Project ......................22

2.1 Online Monitoring Part Feeding System Prototype ........................................24

2.2 PIR Sensor Configuration ...............................................................................25

2.3 Interfacing Circuit of PIR Sensor ....................................................................27

2.4 Laser and Trip Wire Sensor Configuration .....................................................28

2.5 Laser and Trip Wire Sensor Interfacing with Arduino ...................................29

2.6 Sensitivity of LDR Sensor ..............................................................................30

2.7 Load Cell Wheatstone Bridge Configuration .................................................31

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2.8 Load Cell Connection in Wheatstone Bridge Configuration ..........................33

2.9 Load Cell Amplifier HX711 ...........................................................................34

2.10 Mechanical Structure of the Prototype ...........................................................35

2.11 Development of User Authentication Algorithm ............................................38

2.12 Development of Quantity Calculation Algorithm ...........................................39

2.13 Development of Picking Error Detection Algorithm ......................................40

2.14 Development of Assembly Quality Tracking Algorithm ................................41

3.1 Load Cell Calibration Setup.............................................................................43

3.2 Load Cell Calibration Circuit...........................................................................45

3.3 True Load vs Load Cell Voltage ......................................................................47

3.4 True Load vs Load Cell Error Readout............................................................47

3.5 True Load vs Load Cell Readout ....................................................................48

3.6 LDR Symbol Representation ..........................................................................50

3.7 LDR Sensor Photographic View......................................................................50

3.8 LDR Sensor Calibration Circuit.......................................................................52

3.9 Variation of LDR with Light Intensity Setup (A) ............................................54

3.10 Variation of LDR with Light Intensity Setup (B) ............................................56

3.11 Variation of LDR with Light Intensity Setup (C) ............................................57

3.12 Variation of LDR with Light Intensity Setup (D) ............................................58

3.13 PIR Sensor Calibration Result .........................................................................60

4.1 Time Distribution of Feeder Man-Hour ...........................................................62

4.2 Comparison of feeding Man-Hour ( before vs after ) ......................................63

4.3 Human Error Tree for Part Assembly Process .................................................68

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ABBREVIATIONS

A/D Analog to Digital Converter

DC Direct Current

ECU Electronic Control Unit

ED Electro Deposition

GND Ground

HMI Hyundai Motors India

I/O Input / Output

IDE Integrated Development Environment

LED Light Emitting Diode

LDR Light Dependent Resistor

PIR Pyro Electric Infra Red

RFID Radio Frequency Identification

THERP Techniques for Human Error Prediction

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