Original Date: 05/08/1995
Revision Date: 01/18/2007
Best Practice : Intelligent Wire Assembly Station
McDonnell Douglas Aerospace (MDA)-St. Louis has developed and successfully implemented a computer-aided system for connecting wires to their respective electrical connector pinholes. The benefits achieved by the new system, the Intelligent Wire Assembly Station (IWAS), over the superseded Work Director System include a 95% reduction in programming time, a 15% increase in productivity, creation of a paperless operation, and the flexibility to interface with other shop floor systems.
The worker is first shown the computer screen general assembly notes, parts lists, tooling requirements, and splicing details. Next, a connector graphic file from the computer library is displayed on the screen. The display depicts the wire number, color and gage, and the pin number to which it should be connected. The pin number and the appropriate pinhole connector display blinks with the color of the wire to be connected. The display also shows the unused/spare pinholes in a solid color different from the wire colors. After all wires are connected, the IWAS checks if there is any splicing, and then graphically indicates how the wires are to be spliced.
The IWAS can accommodate wire splicing on 98 connector types and over 200 wires per connector. The sequence of hole numbers can be arranged in a linear, circular, or spiral orientation. Additional capabilities include the:
Ability to change assembly sequences with just a change in the data file Ability to show previous operations
Ability to handle a small batch job with no programming
Automatic generation of splicing graphics
Capability to walk forward and backward while assembling wire
Reliability of near 100%
For more information see the
Point of Contact for this survey.