This paper describes reworks issue of a vehicle model (VM) during the production phase in a body in white (BIW), integrates quality limits with optimal allowances of automotive system, and presents analytically a novel perspective that can be used to investigate impacts of the rework in BIW. Rework is one of the major quality issues that can affect the total production optimization negatively; moreover, it can measure the reliability of equipment of a flexible automotive system (FAS). An analytical process has been applied considering quality standard requirements for VMs as a referencing criterion changing relative to the real life measurements and improvement processes. Deviation value (DV) has analytically represented as dimensions measurement and logically involved uncontrollable error factors changing the desired dimensions for both assembling and manufacturing defects with respect to criteria values. During the static phase of production planning, allowable limits for the quality have been measurably expressed in order to provide variability space that can be used latterly for the optimization control process. An analytical heuristic that is based on six sigma technique has proposed to simulate the control process of the deviation variability and investigate the optimal solutions. The contribution of this research work is to introduce a new depiction of the quality factor of products variety with the flexible automated environments that can be used for analytical optimization of the system performance and limits predication of the reworks impact.

Keywords

Quality control, measurement, rework, simulation, optimization system optimization