Delphi uses Negari system to support lean manufacturing and provide production flexibility

Citation

(2002), "Delphi uses Negari system to support lean manufacturing and provide production flexibility", Assembly Automation, Vol. 22 No. 3. https://doi.org/10.1108/aa.2002.03322caf.001

Delphi uses Negari system to support lean manufacturing and provide production flexibility

Delphi uses Negari system to support lean manufacturing and provide production flexibility

Keywords: Automation, Assembly, Automotive

Modular Automation, from Birmingham, has designed and built a new semi-automatic assembly system for Delphi Diesel, of Sudbury, that complies with the company's lean manufacturing principles (see Plate 1).

The system is the fourth line supplied by Modular Automation for the same application. The three previous lines were supplied while the company was Lucas Diesel Systems.

The system assembles diesel injector units to the correct tolerance by using precision shims to compensate for machining limitations and the inevitable variations in the tension of the springs used in the injector body. By choosing a shim of exactly the correct thickness, Delphi can vary the opening pressure of the valve to achieve a complete injector assembly that operates correctly first time. The injectors are subsequently wet tested to verify that accuracy.

The additional line is a direct response to an increasing demand for Delphi's products. At each stage, Modular Automation has respected Delphi's principle of balancing the relative benefits of automation against manual assembly. There is no doubt that it is technically possible for all operations to be performed automatically, however, Delphi's lean manufacturing principles require that automation is only introduced where there is a clear quality and economic case to do so.

The new system operates on a Negari principle, which allows production volumes to be varied depending on the number of operators allocated to the line. A single operator can operate all machines in sequence; however, up to four operators can work on the same line to create a proportionate increase in production rates.

This system is intended to provide the production flexibility needed to support the three machines already in service and react quickly to fluctuations in demand for the product. When the product eventually is withdrawn from service, the Negari line will be able to provide service components precisely to reflect demand with the minimum of downtime.

Plate 1 The new manufacturing system for Delphi Diesel of Sudbury, designed and built by Modular Automation, complies with the company's lean manufacturing principles

Modular Automation has vast experience at developing innovative assembly systems using a modular approach and trusted technology. By approaching its business in this practical way it ensures that its systems are realistically priced, effective and utterly reliable.

Enquiries to: William Bourn, Modular Automation, Talbot Way, Small Heath Business Park, Birmingham, B10 0HS, UK. Tel: +44 (0)121 766 7979; Fax: +44 (0)121 766 6385; E-mail: bourn@modular.co.uk