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(2018) 1277–1282
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51st CIRP Conference on Manufacturing Systems

28th CIRP Design

Approach of Optimized Conference,
Planning May 2018,
Process forNantes, France
Exoskeleton Centered
Workplace Design
A new methodology to analyze the functional and physical architecture of
existing products
Christian for*,an
Dahmena,b,c, assembly
Christin Hölzelaoriented product
, Frank Wöllecke a
family
, Carmen identification
Constantinescu b,c

a
BMW AG, Knorrstraße 147, 80807 München, Germany
Paul Stief *,
c
Jean-Yves
b
Fraunhofer Dantan,
IAO, Nobelstraße Alain
12, 70569 Etienne,
Stuttgart, GermanyAli Siadat
IAT Universität Stuttgart, Nobelstraße 12, 70569 Stuttgart, Germany
École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France
* Corresponding author. Tel.: +49-151-601-47985; fax: +49-89-382-70-47985. E-mail address: [email protected]

* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected]

Abstract
Exoskeleton technology is used in manufacturing [1] to support the manipulation of heavy goods in production specific
Abstract
environments. After selecting the most suitable exoskeleton for each specific workstation [2] the next key step includes the
optimization of the workplace design and adjustment of exoskeletons according to the workstation’s boundaries, conditions, and
Inconstraints.
today’s business environment,
The described the trend
impacts withtowards more product
corresponding variety
industry and customization
examples and methodsis unbroken. Due to
should help to understand
this development, the need of
the influence
agile and reconfigurable production systems emerged to cope with various products and product families. To design
from these new technology on strategic production objectives, e.g. sustainability, reduced cost, ergonomics, flexibility, quality, and optimize production
systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to
and so on. KPIs and their assessment methods are performed at all production scales: beginning from high level for whole
analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and
production systems, over production processes, production lines and workplace influences, which are particularly used, applied
nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production
and needed on task-level. Therefore, new exoskeleton based criteria and methods for process planning are discussed intensively.
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster
They are used to monitor and especially, to optimize the productions impacts by the planning department and responsible
these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable
engineers by this presented generic approach. These work present exoskeleton specific impacts define resulting and relevant
assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
criteria andanalysis
a functional corresponding assessments
is performed. Moreover, methods.
a hybridBased on the
functional andmatching
physical methodology ExoMatch
architecture graph (HyFPAG) [2] isa suitable
the outputexoskeleton
which depictsforthe
the presented example workplace is (pre)selected. With known impacts, the influences and criteria as mentioned
similarity between product families by providing design support to both, production system planners and product designers. An illustrative before, the
novel planning
example and design
of a nail-clipper approach
is used helps
to explain to optimize
the proposed processes An
methodology. andindustrial
the workflow by rescheduling
case study on two product and in consideration
families of
of steering columns of
suitability, strength
thyssenkrupp and weaknesses
Presta France is then carriedofout
exoskleleton
to give a firstcentered
industrialworkplaces.
evaluation ofThe
the content
proposedand relevance of this approach is based on
approach.
©experience
2017 The Authors. Published by Elsevier B.V.
from industry.
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018.
© 2018 The Authors. Published by Elsevier B.V.
Keywords:
Peer-reviewAssembly; Design method;ofFamily
under responsibility identification
the scientific committee of the 51st CIRP Conference on Manufacturing Systems.

Keywords: Exoskeleton; Productivity; Flexibitlity; Qualification; KPIs; Ergonomics; Magic Triangle; 3d-Assessment; Planningmodel; Suitability Of Applicaton

1. Introduction of the product range and characteristics manufactured and/or

1. Introduction and State-Of-The-Art of Exoskeleton assembled
technologyinisthis
the system.
steady-cam In this context,
principle theinmain
used challenge
the film industryin
Technology
Due to the fast development in the domain of (see Fig. 6). Exoskeletons either support the
modelling and analysis is now not only to cope with single whole body [8],
communication and an ongoing trend of digitization and specific areas
products, of theproduct
a limited body (legs
rangeinor Fig. 5, trunk
existing in Fig.families,
product 4, arms
Exoskeletons
digitalization, are dressed enterprises
manufacturing external and are support the body
facing important in Fig. 3) or can be modular [9]. There are several
but also to be able to analyze and to compare products to define research
movement like a power suit or at least as
challenges in today’s market environments: a continuing an orthosis. The projects
new which
product investigate
families. It cantheir innovative
be observed thatpotential
classical[10, 11].
existing
concept was officially mentioned for the first
tendency towards reduction of product development times andtime in 1966 [3]. As a result, many concepts and applications are published
product families are regrouped in function of clients or features. by
Early uses and developments were found in the military
shortened product lifecycles. In addition, there is an increasing sector industry, especially within the field of aerospace
However, assembly oriented product families are hardly to find. [12],
[4, 5] to of
demand enhance the strength
customization, of soldiers.
being Medical
at the same timeexoskeletons
in a global automotive [13–16]
On the product familyandlevel,
logistics [17, differ
products 18]. mainly
Most of the
in two
competition with competitors all over the world. during
were developed to support people with disabilities their
This trend, applications used in industry are smart passive
main characteristics: (i) the number of components and (ii) the exoskeletons
rehabilitation process and their everyday
which is inducing the development from macro to micro life [6, 7]. The (weight
type 2-9 kg) for (e.g.
of components low mechanical,
compensation/supporting force up to
electrical, electronical).
motivation to use exoskeletons in industry
markets, results in diminished lot sizes due to augmentinghas two different 10Classical
kg [19]. Those exoskeletons have a solid anthropomorphic
methodologies considering mainly single products
reasons:varieties
product optimization of humantoergonomics
(high-volume low-volumeand optimization
production) [1]. structure
or to redirect
solitary, already the forces.product
existing However, there is
families additional
analyze the
To cope with this augmenting variety as well as toexoskeleton
of the production system. One popular example of be able to product structure on a physical level (components level)3)which
interest to implement active exoskeletons (see Fig. with
identify possible optimization potentials in the existing causes difficulties regarding an efficient definition and
production
2212-8271 ©system,
2018 The it is important
Authors. Publishedtobyhave a precise
Elsevier B.V. knowledge comparison of different product families. Addressing this
Peer-review under responsibility of the scientific committee of the 51st CIRP Conference on Manufacturing Systems.

2212-8271©©2017
2212-8271 2018The
The Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V. B.V.
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th 51stDesign
CIRP Conference
Conference2018.
on Manufacturing Systems.
10.1016/j.procir.2018.03.185
1278 Christian Dahmen et al. / Procedia CIRP 72 (2018) 1277–1282
Christian Dahmen et al. / Procedia CIRP 72 (2018) 1277–1282 1279
1280 Christian Dahmen et al. / Procedia CIRP 72 (2018) 1277–1282
 Christian Dahmen et al. / Procedia CIRP 72 (2018) 1277–1282 1281
C. Dahmen, C. Hölzel, F. Wöllecke, C. Constantinescu / Procedia CIRP 00 (2018) 000–000 5

7. Outlook 21.12.2017.
[13] Joanne Perry. Man or machine? - Automotive
The presented approach hast to be further elaborated. The Manufacturing Solutions.
next steps will be application, practicability and evaluation of https://automotivemanufacturingsolutions.com/technology
this method. An autonomous recommendation for action is a /man-or-machine. 21.12.2017.
possible solution after developing optimization-functions for [14] Volkswagen AG. Audi Produktion: Rückenschonend
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transfer to other technical and innovative assistance systems in oskelett.html. 21.12.2017.
production might be interesting. [15] Susanne Nördinger. Exoskelette: Mechanische Muskeln
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Acknowledgement
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