Keeping it simple
Project challenges
In the world of automated assembly - especially for vehicle power units - maximising the use of costly capital equipment is crucial. It's about boosting efficiency, cutting back on manufacturing complexity and driving down costs.
Business challenge
Product Innovation
Sector
Power & Energy
Technology or capability
Product Design
MTC uses its ground-breaking formula to improve assembly process efficiency through design.
MTC engineers have crafted an innovative formula to simplify designs and revolutionise the assembly process. DOZO/FRAG is a game-changing approach which explores the best assembly orientation for a product. DOZO (Design for One-Way or Zero turnover assembly) ensures a more efficient and streamlined process. Meanwhile FRAG (Fastener Rationalisation Assessment Guidelines) scrutinises the number of fasteners used, slashing part numbers and costs, making assembly much simpler.
Teaming up with REE Automotive, MTC was able to test the DOZO/FRAG methodology on the company's innovative REEcorner ® product.
The Challenge
All too often, product design focuses solely on the product, overlooking the challenges and inefficiencies that can arise during assembly. But in the world of automated assembly - especially for vehicle power units - maximising the use of costly capital equipment is crucial. It's about boosting efficiency, cutting back on manufacturing complexity and driving down costs.
MTC's Solution
MTC has applied the DOZO/FRAG method to REE's corner unit with the objectives of:
- Optimising assembly operations.
- Pinpointing the best assembly orientation.
- Identifying the ideal assembly starting point.
- Streamlining fastener types and quantity
Our MTC 'DOZO' offering has been applied to optimise the design and assembly process of the REEcorner, delivering enhanced efficiency and transforming our in-house innovation into tangible benefits for our customers.
Adam Brown, Technology Manager - MTC
The Outcome
- Using DOZO and FRAG guidelines has dramatically cut down assembly time and complexity.
- Proposed solutions are set to drastically reduce the need for extra handling equipment and complex assembly processes.
- Assembly sequence improvements have slashed turnover and re-orientation operations by up to 60 per cent.
- A leaner assembly sequence has eliminated unnecessary operator movements ensuring tasks are performed with greater ease and efficiency.
Benefits to the Client
- By embracing one-way assembly, utilisation of expensive capital equipment is maximised.
- A staggering 75 per cent reduction in fastener types, thanks to FRAG, has streamlined operations and cut down on fastener-related tasks.
- Manual re-orientation during assembly has been virtually eliminated, speeding up production and balancing workloads across all stages.
- The leaner assembly sequence has led to fewer operator movements, shorter waiting times, and significant reductions in inventory and waste.
