Advanced SearchSearch Tips
A Reconfigurable Mixed-Model Assembly System of Cockpit Module using RFID/ZigBee Protocol
facebook(new window)  Pirnt(new window) E-mail(new window) Excel Download
 Title & Authors
A Reconfigurable Mixed-Model Assembly System of Cockpit Module using RFID/ZigBee Protocol
Koo, Ja-Rok;
  PDF(new window)
Mixed-model assembly line has been widely used in automotive assembly industry to quickly respond the diverse product demands. But, this model can lead to part confusion, which is a source for assembly errors when parts are physically interchangeable in a mixed-model assembly line. With the recent application of new technologies such as radio frequency identification (RFID) and ZigBee wireless sensor network (WSN) to the assembly process, real-time information has become available in this manufacturing systems through IT infrastructures. At first, this paper presents an RFID application for assembly processes, specifically, for a mixed-model assembly line. Thus, to ensure that parts be picked accurately, each cockpit module on the assembly line is attached with a RFID tag and the tag is scanned using a RFID reader and recognizes the vehicle, and each part of the cockpit module is attached with a barcode and the barcode is scanned by a barcode reader and each part is identified correctly for the vehicle. Second, this paper presents a ZigBee wireless sensor network (WSN) protocol-based application for a reconfigurable mixed-model assembly line of cockpit module to reduce the assembly errors and the cost of the change/reconfiguration on the assembly lines due to the various orders and new models from the motor company, avoiding the wiring efforts and inconvenience by wiring between the several RFID devices and the IT server system. Finally, we presents the operation results for several years using this RFID/ZigBee wireless sensor network (WSN) protocol-based cockpit module assembly line.
Assembly errors;Cockpit Module;reconfigurable mixed-model assembly line;RFID;ZigBee wireless sensor network (WSN);
 Cited by
S.J. Hu, J. Ko., L. Weyand, H.A. Elmaraghy, T.K. Lien, Y. Koren, H. Bley, G. Chryssolouris, N. Nasr, M. Shpitalni, "Assembly system design and operations for product variety", CIRP Annals-Manufacturing Technology, pp.1-19, 2011.

Zhixin Yang, Wei Xu, Pak-Kin Wong, Xianbo Wang, "Modeling of RFID-enabled Real-time Manufacturing Execution System in Mixed-model Assembly Lines", Mathematical Problems in Engineering, Article ID 575402, pp.1-40, 2014. DOI:

Rasmus Personne, Victor Matinlassi, "Part assurance in a mixed-model assembly line", Master of Science Thesis, KTH Industrial Engineering and Management ITM, pp.1-65, 2014.

Nils Boysen, Malte Fliedner, Armin Scholl, "Sequencing mixed-model assembly lines: Survey, classification and model critique", European Journal of Operational Research No.192, pp.349-373, 2009. DOI: crossref(new window)

Jayashankar M. Swaminathan, Thomas R. Nitsch, "Managing Product Variety in Automobile Assembly: The Importance of the Sequencing Point", Interface vol.37, No.4, pp.324-333, July-August, 2007. DOI: crossref(new window)

Gaukler, Gary M. Hausman, Warren H., "RFID in mixed-model automotive assembly operations: process and quality cost savings", IIE Transactions, Nov., 2008. DOI: crossref(new window)

Jarok, Koo, "Error-Preventing Monitoring System using RFID in the Mixed-Model Automotive Parts Assembly Line", The Korea Academia-Industrial cooperation Society, Vol.10, No.12, pp.3863-3869, 2009. DOI: crossref(new window)

Brent Cheldelin, Kosuke Ishii, "Mixed Model Assembly Quality: An Approach To Prevent Human Errors", Proceedings of IMECE, pp.1-12, 2004. DOI: crossref(new window)

V. P. Jaganathan, N. Ganesh Kumar, "Implementation of RFID Technology in Assembly Line for Part Traceability", Proceedings of the National Conference on Manufacturing Innovation Strategies & Appealing Advancements, pp.1-8, April 19, 2013.

Suk-Keun Cha, Jeong-Hoon Lee, Han Gyu Kim, Joon Jae Yoo, Jung Hoon Kang, Dong Hoon Kim, Jun Yeob Song, "An Auto-Configuration of 4M Group Management Using Wireless Sensor Networks", Wireless Sensor Network, pp.402-410, 2010.

Hsin-Mu Tsai, Cem Saraydar, Timothy Talty, Michael Ames, Andrew Macdonald, Ozan K. Tonguz, "ZigBee-based Intra-car Wireless Sensor Network", IEEE Xplore, July, 2007

Suhas Chakravarty, Varun Jain, Nakul Midha and Prashant Bhargava, "Low-Cost Driver Assistance Using ZigBee/IEEE 802.15.4",, pp.78-82.

K. Pavani, M.S. Madhan Mohan, "Implementation of CAN and ZigBee networks based industrial monitoring and control applications", International Journal of Engineering Research & Technology (IJERT), pp.1-5, July, 2012

Cha Jang Mok, "The Assembly Defect Preventing Monitoring System using RFID in the Cockpit Module", Master Thesis, Institute of e-Vehicle Technology, Univ. of Ulsan, 2006.

IEEE Std 802.15.4-2003, Wireless Mac and Phy Specifications for LR-WANS, pp.45-48.

Patent No.10-0783598, "Control device and method for Cockpit Module Production using RFID signals", 2007.

Patent No.10-0846453, "Cockpit Module Production Device using RFID signals", 2007.

Patent No.10-1178413, "Cockpit Module Production System and Production Methods using ZigBee Protocol", 2012.