Chisholm Institute TAFE

Bachelor of Engineering Technology

Assignment 1 by Kushal Ramnarain R200981124

ADVANCE MANUFACTURING

Contents
1.0

Introduction...................................................................................................................... 3

2.0 Assembly line Production..................................................................................................... 4

2.1 Headlight Components...................................................................................................... 4

1.0 Introduction
This report has been written to describe the assembly line in the manufacturing of headlight.
A headlight manufacturer produces three types of car headlight and production demand for
six month has been given. By using advance manufacturing concepts an assembly layout was
designed.

2.0 Assembly line Production

In this section the following will be described: components used in the manufacture of the
headlight, the order in which each assembly are done and the equipment used.
3

2.1 Headlight Components

The following components are used in the manufacture of the headlight:
Rear housing:
The rear housings are built in house
Wire harness:
The wirings are ordered from a supplier
Bulbs:
The bulbs are ordered from a supplier
Socket clips:
The socket clips are ordered from a suppler
Reflector:
The reflectors are manufactured in house
Ballast for xenon lamp:
The ballasts are ordered from a supplier
PCB for LED lamp:
PCB for the lamps are ordered from a supplier
Lens
The lens for the lamps are built in house
The main focuses of the factory is headlight assembly components like nuts, bolts, screws,
bulbs, electrical harness and electronics components are ordered from suppliers. The only
components that are manufactured in house are the housings, reflectors and lens.

2.2 Equipment used in the assembly process

The following equipment are used:
Injection moulding machine:
The factory have four injection moulding machines. The first machine is to manufacture the
headlight housing. The second machine to manufacture the reflectors .The third machine is
for xenon and halogen lamps front lens. The fourth machine is to manufacture the LED front
lens.
4

Reflector installation machine:

The reflector machine is an autonomous machine used to install the reflector in the housing. It
requires an operator to insert the housing in its jig and press the start button
Automotive glue spreading/ lens press machine:
This machine automatically spread glue around the housing and presses the lens in .An
operator is required to put workpiece in and press the start button
Leakage testing machine:
Once the headlight has been assembled it is put in a leakage testing machine to check for
leaks. An operator is required to put workpiece in and press the start button
Light aiming adjustment machine:
The light aiming adjustment machine is used to automatically adjust the intensity of low
.medium and high beam.
Also various hand tools like automatic screw drivers are used during the manual operations of
the assembly process.

2.3 Tasks in the assembly process

The table below shows the tasks involves in the headlights assembly in their respective steps.

Task description

Task code

Put housing into fixture (manual)

Connect wire harness (manual)
Install relfector (Automated)
Insert corner lamp(manual)
Insert park lamp(manual)
insert signal lamp (manual)
insert headlight bulb (manual)
Attach inner lens (automated)
assemle PCB for LED lamp (manual)
Attach balast for Xenon lamp (manual)
Attach outer lens to and housing (semi
Automated)

A
B
C
D
E
F
G
H
I
J
K

Predeces
sor
_
A
B
C
D
E
F
G
H
H
I,J

Leakage testing (semi automated)

Light aiming adjusting (semi automated)
final visual inspection and packing in box
(manual)

L
M
N

K
L
N

2.4 Labour and cycle time

The factory employs three assembly operators and the time taken for each operator to
complete their assigned tasks along the production line in one cycle is shown in the table
below.
5

Compo
nents
Name
Rear
housing

Wire
harness
corner
lamps

park
lamp
bulb
signal
lamp
bulb
headligh
t bulb
Socket
clips
Reflecto
r

Ballast
for
xenon
lamp

Task
Descrip
tion

Ta
sk
Co
de

oper
ator

Put
housing
into
fixture
(manual)
Connect
wire
harness
(manual)
Install
reflector
(Automat
ed)

staff
1

staff
1

Insert
corner
lamp(ma
nual)
Insert
park
lamp(ma
nual)
insert
signal
lamp
(manual)
insert
headlight
bulb
(manual)
Attach
inner
lens
(automat
ed)

assembl
e PCB for
LED
lamp
(manual)

Machi
ne

Time Taken to
perform each
task (seconds)
Halo Xe
LE
gen
non D
lamp lam la
p
m
p
5
5
5

10

10

10

staff
2

staff
2

staff
2

staff
2

reflecto
r
installa
tion
machin
e

Automo
tive
glue
spread
and
lens
press
machin
e
staff1

15

PCB for
LED
lamp

Halogen
lamp
front
outer
lens

Xenon
lamp
front
outer
lens
LED
front
outer
lens

Attach
ballast
for
Xenon
lamp
(manual)
Attach
outer
lens to
and
housing
(semiautomat
ed)

staff
2

staff
3

Leakage
testing
(semiautomat
ed)
Light
aiming
adjusting
(semiautomat
ed)
final
visual
inspectio
n and
packing
in box
(manual)

staff
3

staff
3

staff
3

15

Automo
tive
glue
spread
and
lens
press
machin
e
Leakag
e
testing
machin
e
Light
aiming
adjust
ment
machin
e

Total
assemb
ly time
of each
lamp
types
in sec
Total
assemb
ly time
of each
lamp
types
in min

10

10

10

60

60

60

60

60

60

15

15

15

189

204

20
4

3.15

3.4

3.4

Time taken by each staff during one cycle (seconds)

Staf

Halogen lamp

Xenon lamp

LED
lamp

25

25

30

25

40

25
7

30

30

30