Designing Jigs with Enhanced Durability to Streamline the Map Lamp Assembly Process

Abstract

This paper discusses designing and implementing a jig for the assembly workstation on the Polybond line. Child parts like map lamp brackets, external microphones, foam, and wire hardness are installed at the assembly workstation. This project focuses on enhancing job handling to complete the map light bracket installation on the header. Currently, the map lamp bracket installation proceeds without any supervision. This results in inconsistent cycle times and procedural neatness, as it relies on the operator's proficiency, varying from 17 to 19 seconds for skilled operators to 34 to 37 seconds for unskilled operators. This article aims to create a jig that will serve as a guide for the hot glue gun nozzle, thereby improving the work outcome. CATIA V5 was used to complete the design process before the jig prototype was manufactured for testing. When the prototype worked as expected, the actual jig was created using appropriate material to ensure its long-term functionality on the manufacturing line.