Automating the production of the automotive retainer using the rotary indexing mechanism

Abd Rashid, Muhammad Hazim (2015) Automating the production of the automotive retainer using the rotary indexing mechanism. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The current production of automotive retainer in the industry is through conventional process. The process involves the use of manual operation of huge stamping machines and its jigs. This approach requires high involvement of workers in the production line. As a consequence, longer cycle time is required to complete the process. This situation will indirectly lower the production rate. The manual operation in this approach also indicates higher labour cost. To overcome these issues, automating the production of automotive retainer is seen as a potential approach. The main idea of this project is to propose a design concept of automation system for the production of the automotive retainer. The propose concept include the utilization of rotary indexing mechanism. Three stages were involved in this project. Firstly, it involves the study of the related production systems. The study involving reviews on the related production system has been included in this project. The review is to gain the information based on the type of automotive retainer, the production of the automotive retainer in fuel tank, material transfer approach in the production system, tools in design of manufacturing system as well as analysis of the rotary indexing mechanism for automated production systems. The second stage is the design stage. The design and simulation process of the developed automated system involved the use of CATIA software. The final stage involves with the simulation and analysis of the simulation outcomes. Once the automated production system has been designed, the analysis process is performed using SolidWorks software. This analysis include a thorough comparison on the current cycle time and production rate with the proposed automation version. The results show the improvement of the cycle time as well as the production rate. The outcome of this new automated approach in producing the automotive retainer is hoped to benefit the industry in the future.

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