MEE40005

Faculty of Engineering, Computing and Science

MEE40005
Human Factors

Identify and elaborate on the factors in the

manufacturing assembly process

Student Name: Wong Cheng Zhou

Student ID: 100074021

Group: Monday 4pm – 6pm

Date: 20/05/2020

WONG CHENG ZHOU (100074021) 1

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Introduction
An assembly line is a manufacturing process in which parts are added as the semi-finished
assembly moves from workstation to workstation where the parts are added in sequence until
the final assembly is produced. There are 5 factors applied in the manufacturing assembly
process of Ford-F150 truck assembly, which are visual, auditory, display, control and
workplace design.

1. Visual

During the assembly and put on of the logo and stickers on the truck beds, the usage
of light is important as it makes it convenient for the operator to apply stickers on
different model of Ford F-150 truck. Before applying the stickers, the truck beds are
transferred to the tunnel and heat lamp is used to warm the truck bed metal.

Through undergoing paint inspection, the paint shop inspector will inspect the car
paint quality control through the assembly line. Therefore, the usage of lighting is
important for operator to check the quality of the colour and prevent any defects and
flaws. After that, the truck will go through final checking under special light for the
last overall inspection on the whole car quality including car body and paint.

2. Auditory

Ford assembly factory provides 3M earplug which will control the noise exposure
level and the risk of hearing loss in the workplace. Meanwhile, the effectiveness of
3M earplug is the maximum when the ear buds fit properly. This 3M earplug contains
built-in comfort which ensures all-day comfort of the operator and protection in a
wide range of working environments.

At the rubber body mounts part, the workers are isolated from noise and vibration by
using electric wrenches which help to reduce the noise and cordless power tools.
The primary function of an electric wrenches is to deliver high torque to nuts and
bolts with low noise.

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3. Display

The computer screen is a common function as it provides details that explains

function of the button and displays the name of the items. During the F-1150 door
assembly part, the screen is used to determine the small parts whether it belongs to
which door. To conclude, the operator will follow the corresponds number or code to
install the parts such as handle and clips to the door. Meanwhile, it is to ensure the
door are installed right in different specification of F-150 truck. Among the body
shop, paint shop and final assembly shop, the sticker signs are from a variety of
messaging, sizes, and formats. These stickers will help operations function more by
alerting operator to hazards, emergency switches, special zones, conveyor safety
issues or unexpected movement in designated robot workspaces. There are also
barcode solutions for the small parts before assembling the door part. According to
ford assembly line, barcodes provide a simple, direct, accurate, reliable and cost-
effective way of communicating and tracking information (data) about the part
information.

4. Control

Windows and weather stripping insulation part will pass through the vision system
(digital scanner) after finishing. The vision system is an electronic quality check. For
example, the digital scanner will snap a picture for every part that passes through
and verifies the information that is contained on the ticket through the barcode.
Besides, the handheld electric bolt gun is a kind of automated machines that is used
to tight the bolts together with the parts. Combined with the handheld electric bolt
gun, a computer system is combined and linked to monitor and pops out the
tightness result of the bolt. For example, TENSOR S4/S7torque tool nut runner
drives controller benefits of controlled tightening and advanced electric systems
throughout assembly operations.

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5. Workplace design

There are many ways in which a workplace can be adjusted. The following summarizes four
general approaches to workplace adjustment that should be considered in workplace.

 Forklift trucks are standbyed around the assembly line and the heavy part such
as chassis are sent to the specific assembly point.

 Adjusting the worker position relative to the workplace.

 ‘Happy seat’ a swivel chair enables workers to sit in comfort on the

production line when assembling cars. The seat allows workers to sit and glide
into the car while fitting pedal boxes, install seat and install clips and bolts on
the bottom of the trucks.

 Elements of the factory floor are also operator-friendly where part of the floor
is covered in each wood. This kind of wood is multi-layered which can reduce
the impact during long hour of working.

Component arrangement is also a part of a workplace designer’s task which is to arrange the
displays and controls, equipment and tools, and other parts and devices within some physical
space. According to Ford-150, assembly factory is separated into 3 stations, which are body
shop, paint shop and final assembly shop. The following are the function of the shops.

 Body shop- to assemble various parts produced in press shop using welding and other
processes.
 Paint shop- spray various colour and layers of coating on vehicles.
 Final assembly shop-to assemble the two main parts, which are casing and chassis
together.
These stations enable Ford factory to increase the production per day.

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Reference List

‘Atlas Copco TENSOR S$/S& DC torque tool nut runner drive controller PF3007-C-HW’,
ebay, viewed on 20 May 2020, < https://www.ebay.com/itm/Atlas-Copco-TENSOR-S4-S7-DC-
Torque-tool-nut-runner-drive-Controller-PF3007-C-HW-/123462678022 >

‘Design for manufacturing and assembly(DFMA)’, Siemens Ingenuity for life, viewed on 20
May 2020, < https://www.plm.automation.siemens.com/global/en/our-story/glossary/design-
for-manufacturing-and-assembly-dfma/53982>

‘Worker Health & Safety’, 3M science applied to life, viewed on 20 May 2020, <
https://www.3m.com/3M/en_US/worker-health-safety-us/personal-protective-equipment/foam-
earplugs/>

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