Simulation and Design of Production Jigs for Bus Chassis

Bus manufacturing is one of important automobile industries. In small enterprise, bus chassis is based on manually production. The manual production is low production rate and long throughput time. Moreover, the manual processes are also difficult to make standardization and lead to maintenance difficulty. Therefore, this study aims to design production jigs for bus chassis and use finite element method to analyze the jigs. Production rate with various production scenarios also analyzed. 2 models of Chassis technical data and information was collected from bus manufacturer. The chassis was break into sub-assemblies. 4 Jigs were designed for production of all sub-assemblies. Jigs design was built and assembled on SolidWork, finite element method was carried out by using ANSYS Workbench. Simulation results show that the minimum safety of factor occurs with factor 1.94. Re-design of jigs yield an improvement on the weak point with safety of factor 4.20. Standard time for production of each sub-assembly was calculated. It was found that production rate of 2.3-2.8 chassis/day is achieved based on 2-man working with 4 jigs. The 4-man working yields about 75% increasing in production rate with also increase of %idle time compared to 2-man working scenario. 6-man working with additional 2 jigs found that production rate of 5 chassis/day.