Purpose

Electrical defects cover an important part of assembly defects and strongly affect the vehicle system performance. Almost 40% of assembly defects are classified as human errors and electrical connection failures represent a significant part of them. Humans still remain a cost-effective solution for the flexible manufacturing systems with increasing product complexity. So, understanding human behaviors is still a challenging task. The purpose of this study is to define, prioritize and validate the critical factors for the complexity of electrical connector plugin process.

Design/methodology/approach

The critical variables were defined by the expert team members. The required number of measurements and variables were revised resulting preliminary analysis of binary logistic regression. After the revision of measurement plan, the list of critical input variables and the mathematical model were defined. The model has been validated by the fitted values of the residuals (FITS analysis).

Findings

To the best of the authors’ knowledge, this is one of the limited studies, which defines the critical factors for electrical connection process complexity. Female connector harness length, connector width/height/length differences, operator sense of correct connector matching and ergonomy were defined as the factors with the highest impact on the failure occurrence. The obtained regression equation strongly correlates the failure probability.

Practical implications

The obtained mathematical model can be used in new model development processes both for the product and assembly process design (ergonomy, accessibility and lay-out).

Originality/value

The obtained risk factors demonstrated a strong correlation with assembly process complexity and failure rates. The output of this study would be used as an important guide for process (assembly line ergonomy, accessibility and lay-out) and product design in new model development and assembly ramp-up phases.

中文翻译：

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电连接器组装中的故障预测：汽车组装过程中的案例

目的

电气缺陷覆盖了装配缺陷的重要部分，并严重影响了车辆系统的性能。几乎40％的组装缺陷被归类为人为错误，而电气连接故障占了很大一部分。对于不断增加的产品复杂性，人为柔性制造系统仍然是一种经济高效的解决方案。因此，了解人类行为仍然是一项艰巨的任务。这项研究的目的是为电连接器插件过程的复杂性定义，确定优先顺序并验证关键因素。

设计/方法/方法

关键变量由专家组成员定义。修改了所需数量的测量值和变量，对二进制逻辑回归进行了初步分析。修改测量计划后，定义了关键输入变量列表和数学模型。该模型已通过残差的拟合值进行了验证（FITS分析）。

发现

就作者所知，这是有限的研究之一，它定义了电连接过程复杂性的关键因素。母头连接器线束长度，连接器宽度/高度/长度差异，操作员正确连接器匹配感和人体工程学被定义为对故障发生影响最大的因素。所获得的回归方程与失效概率密切相关。

实际影响

所获得的数学模型可以用于产品和装配过程设计的新模型开发过程（人体工程学，可访问性和布局）。

创意/价值

所获得的风险因素表明与装配过程的复杂性和故障率有很强的相关性。这项研究的结果将作为新模型开发和装配加速阶段中的过程（装配线人机工程学，可及性和布局）和产品设计的重要指南。