Design and Optimization of Lean Manufacturing System Based on Collaborative Robots

The traditional production process of small order batches and a wide variety of products mainly relies on a large number of manual workers, which has high production costs, low efficiency, and poor flexibility. In order to solve the above problems, a LEGO car assembly production project based on a collaborative robot has been designed. A human-machine collaboration scheme is adopted. By calculating the cost, UPPH, production line balance rate, and other indicators of this scheme, it is determined that it can improve and optimize manual operations. In practical use, the use of Techman collaborative robot (TM5-900) has improved the flexibility of the production line, increased the efficiency of the production line, shortened the product delivery cycle, and enhanced the safety and yield of workers' operations. Significant achievements have been made in cost control and efficiency improvement. By comparing and analyzing the efficiency and cost with the original pure manual production, it can be found that this plan increases the UPPH of car A by 73.9% and car B by 70.9%, with a production line balance rate of over 90%. The investment cost can be recovered within two years. Finally, a reference design method for flexible production lines was provided, including how to plan, design, and use collaborative robots to work together with workers, and a reference program for collaborative robots was provided.