A Method to Design Assembling Lines for Super Premium Efficiency Motors

Producing highly efficient electric motors remains a challenge nowadays. Given that the legislation in the field requires the transition to the production of engines with increased efficiency, for manufacturing companies, switching from one generation of engines to another can be a difficult task. This paper analyzes ways to adapt the assembly of engines of the IE4 generation starting from the assembly lines of the engines of the previous generation, IE3. The analysis of the assembly process covers both the operator training part and the actual assembly part. Ten possible variants for the assembly line and specific decisional variables have been defined. The decision to choose the optimal assembly configuration was made using as management tools the matrix of consequences and utilities. The validation of the theoretical model of the assembly line was carried out through a case study built for two classes of electric motors, namely G90 and G180. For a total production of IE4 electric motors of 20,000 parts/month, the analyzed variants, respectively, the two sizes (G90 and G100) represent 35% (7000 parts/month) of the G90 size and 22% (4400 parts/month) the G100 size. The aim is to provide a new modular assembly concept, which depending on the orders, can use, as given in the conclusion of this article.