Value Stream Optimization in UAV Assembly Based on the Integration of Lean Manufacturing, Simulation Modeling and Elements of Robotics

Abstract

This article presents the results of optimizing the series assembly process of unmanned aerial vehicles (UAVs) at a defense industry enterprise using lean manufacturing tools and simulation modeling in the Any Logic environment. Using value stream mapping, timekeeping, and a workday photograph, the main types of losses were identified and quantified, including waiting time, unnecessary transportation, defects, and inefficient personnel movements. A simulation model was developed that justified the transition from a slipway to a flow assembly organization, dividing the process into 18 sequential stations. Computational experiments determined the optimal number of workposts at each station, which increased daily output 5.7-fold without increasing the headcount, reduced worker workload variance from 0.007 to 0.004, and created an employee float of 70%. The economic effect of eliminating losses amounted to 31.6 million rubles. Building on the obtained results, we propose approaches to transitioning to lean robotic manufacturing, including the automation of interoperational logistics using automated guided vehicles, the implementation of algorithms for continuously variable buffer zone control to minimize work-in-progress, noise emission monitoring in robotized areas, and a qualimetric assessment of robotization priorities based on operational coefficients. The developed approaches can be replicated at defense industry enterprises for organizing multi-product, continuous assembly of high-tech products.