Introduction to Assembly 101

adherents

An object that is bonded to another object with an adhesive. Adherents can be made of similar or dissimilar materials.

adhesive bonding

The joining of two or more materials using adhesive substances such as pastes, gels, and tape. Adhesive bonding can be used to join similar and dissimilar materials.

adhesives

A chemical substance used to bond two or more materials together. Adhesives are made of nonmetallic materials.

alloys

A material created by intentionally mixing two or more substances, one of which must be metal. Alloys combine the desirable properties of the base materials.

assembler

A person who assembles parts. Assemblers perform mechanical fastening, adhesive bonding, and welding tasks.

assembly

The process of joining components together into a larger or completed part. Assembly methods include mechanical fastening, adhesive bonding, and welding.

Assembly lines

An arrangement of workstations used to mass produce products in stages. Assembly lines are a main feature of assembly sites.

Assembly site

The place where assembly is performed. Assembly sites often consist of workstations arranged in assembly lines.

automated assembly line

An assembly line in which the majority of tasks are performed by automated machines. Automated assembly lines require little or no human interaction.

automation

The use of self-regulated equipment, processes, or systems that meet manufacturing requirements with limited human intervention. Automation is an efficient means of assembly.

balancers

A flexible, retractable line of strap or rope used to support the weight of tools in some manufacturing processes. Balancers are a form of lanyard used for heavy tools.

base metals

A metal component to be fused with another by welding or other methods. Base metals influence weld type and the welding process.

bolts

A cylindrical threaded fastener with a head that usually mates with a nut. Bots usually have blunt ends.

bottleneck

A point of congestion during the production process. Bottlenecks limit the flow of production.

brazing

A process in which a filler metal is melted at a temperature above 840°F (449°C) but below the melting point of the base metals to form a joint between two base metals. Brazing can be used to join dissimilar metals like silver, aluminum, copper, nickel, and gold.

brittle

Inflexible or unwilling to be drawn, stretched, or formed. Brittle materials break instead of bend when subjected to force or pressure.

carousel systems

An automated assembly system that combines the features of dial and in-line index systems. Carousel systems make it possible to produce complex parts efficiently.

Cells

An arrangement of workstations structured around a stage of a manufacturing process. Cells encourage smooth part flows and use space efficiently.

chassis

A rectangular frame on which robots are mounted beside a conveyer on in-line index and carousel systems. The chassis of an automated assembly machine holds tooling and keeps workstations together.

chemical reaction

A process in which one or more substances are changed into another substance. Chemical reactions cause adhesives to cure.

clamps

A workholding device with jaws that holds a tool or workpiece in place. Clamps hold an object by using inward pressure by tightening.

coatings

A protective film applied to the surface of an object to improve its functionality or bond it to another material. Coatings improve a part's ability to withstand environmental hazards such as extreme heat or flying debris.

conditioning

A process that prepares the surface of a part for subsequent operations, such as adhesive bonding. Conditioning creates a rough surface on adherents that makes the adhesive bond more effective.

conveyors

A moving strip of material that carries parts or other components from one area of an assembly site to another. Conveyors improve the efficiency of an assembly line by keeping parts moving.

corrosion

The deterioration of a material caused by a chemical reaction. Corrosion weakens materials and can cause them to fail.

coupling agent

A compound that improves the bond between two adherents. Coupling agents can be used to pretreat surfaces before an adhesive is applied.

cracked welds

A visible fracture or point of separation in the surface of a weld. Cracked welds must be repaired or the welded part must be discarded.

curing

The process during which an adhesive undergoes a chemical reaction and becomes a solid. Curing may require pressure, heat, UV radiation, or a specific amount of time.

curing agent

A chemical that causes a polymer or resin to harden. Curing agents are used in epoxies.

dial index systems

An automated assembly system designed so that operations are performed as an index table or column rotates parts from workstation to workstation. The dial index system is also known as the rotary index system.

disassembly

The process of taking apart a product, often with the intention of reassembly. Disassembly is made possible using mechanical fasteners.

Electric tools

A tool that is powered by electricity. Common electric tools include drills and screwdrivers.

epoxies

A high-strength adhesive made from a polymer and a curing agent. Epoxy is resistant to heat.

Ergonomics

The scientific study of equipment, workspace, and production environment design to increase comfort, safety, and productivity. Ergonomics can be applied to any workplace.

fasteners

A device that holds two or more objects together or locates them in relation to each other. Common fasteners include screws, bolts, rivets, and nails.

filler metal

Metal that may be added to a joint during a fusing process like welding, soldering, or brazing. Filler metal adds to the strength and mass of a welded joint.

framework

A structural support on which other components are attached. Framework is often made of metal bars that are joined together with welds.

fumes

Airborne particulate matter that behaves similar to a gas. Welding fumes include particulates from the electrode, base metal, and any coatings included on the welding materials.

hinges

A mechanical joint capable of movement. Hinges can be attached with fasteners.

impact drivers

A power-driven tool that forces large fasteners into an object. Impact drivers are commonly pneumatic tools.

index table

The circular component of a dial index machine on which parts are placed. The index table rotates to position parts at workstations.

in-line index systems

An automated assembly system that moves components in a straight line along a chassis. In-line index systems are used for assembling complex parts.

jigs

A customizable workholding device that holds a tool or workpiece in place. Jigs control the location or motion of a workpiece.

joint

The point at which two materials are attached or joined together. Some joints are permanent, while others can be disassembled and reassembled.

Labor costs

An expense associated with employees, including wages, insurance, taxes, and other compensation. Labor costs can make manual assembly expensive.

lacquer

A coating that assists in the bond between two adherents. Lacquer can be used to pretreat surfaces before an adhesive is applied.

Lanyards

A flexible, retractable line of rope, wire rope, or strap. Lanyards are commonly called balancers in assembly.

Linear

Arranged or moving in a straight line. Linear assembly lines Linear assembly lines consist of workstations that perform tasks in a sequence.

Manual assembly line

An assembly line in which the majority of tasks are performed by assemblers. Manual assembly lines typically rely on assemblers to transfer parts between workstations.

Mechanical fastening

The joining of two or more materials with devices called fasteners. Mechanical fastening is often used for parts that require disassembly and reassembly.

melting point

The temperature at which a material changes from a solid to a liquid. Melting point varies based on the properties of the material.

nail guns

A power-driven tool that forces a nail into an object. Nail guns are commonly pneumatic tools.

Nails

A thin, pointed, non-threaded fastener that is driven into an object with a hammer. Nails are typically used with nonmetallic materials.

non-threaded fasteners

A type of mechanical fastener that does not feature threads. Common non-threaded fasteners include pins, retaining rings, nails, and rivets.

nuts

A fastener with a threaded hole that mates with a bolt. Nuts have internal threads.

parts feeders

A device that separates bulk parts and organizes them onto a conveyer so that a workstation receives only the amount needed for the task at hand. Parts feeders help an assembly line to be efficient.

pins

A thin, often straight, cylindrical non-threaded fastener used to secure the position of two or more machine parts. Pins are inserted through holes.

pneumatic tools

A tool that is powered by compressed air. Common pneumatic tools include nail guns, rivet guns, and impact drivers.

polymer

A material, such as plastic or rubber, made of long chains of molecules. Polymers are used with curing agents to create epoxies.

priming

A step in the adhesive bonding process that prepares a surface for an adhesive. Priming typically involves cleaning the surface and applying a coupling agent, lacquer, or other adhesion-promoting substance.

properties

A characteristic of a material that distinguishes it from other materials. Welding together metals with dissimilar properties can impact the characteristics of the weld.

quality

Conformance to a set of standards or specifications that results in customer satisfaction in a product or service. Quality products are free of defects and meet the requirements of their anticipated use.

reassembly

The process of putting previously disassembled components back together. Reassembly is made possible using mechanical fasteners.

retaining rings

A flat, circular, non-threaded fastener with a hollow center and an open section. Retaining rings, also known as snap rings, position and limit part movement along a shaft or within a hole.

rivet guns

A power-driven tool that forces rivets into an object. Rivet guns are commonly pneumatic tools.

Rivets

A non-threaded fastener that consists of a shank and a head made of deformable material. Rivets are inserted through holes and the shank is formed into a matching head on the other side of the part.

robots

A programmable mechanical device used to perform a variety of complicated, repetitive tasks. Robots are used in automated assembly lines to enable a higher degree of accuracy.

rotary index system

An automated assembly system designed so that operations are carried out at workstations by tooling mounted on a central column or around the periphery of an indexing table. The rotary index system is also known as the dial index system.

screwdrivers

A tool used to fasten or tighten screws. Screwdrivers have a handle on one end and a blade on the other that fits into the recess in the head on a corresponding screw.

screwguns

A tool with multiple cutting edges used to drive fasteners into workpieces. Screwguns are common tools for assembly.

screws

A cylindrical threaded fastener that either fits into a treaded hole or forms threads in a material. Screws may have blunt or pointed ends.

sensors

A device that detects a change in physical and environmental conditions. Sensors allow robots and other devices to interact with their environment and operate with little human intervention.

soldering

A joining process in which a filler metal is melted at temperatures below 840°F (449°C) to form a joint between two base metals. Soldering is often used for delicate projects such as jewelry and electronics.

staples

A non-threaded fastener that is typically u-shaped. Staples have no threads and can only be used once.

stress

A force that attempts to deform an object. Common forms of stress include compression, shear, and tensile.

strip

A condition in which a fastener's threads become damaged and ineffective. Fasteners strip when excess torque is applied or when their threads become misaligned.

structural adhesive

A type of heavy-duty adhesive used for large-scale projects. Structural adhesives are durable and can withstand heavy loads.

Threaded Fasteners

A type of mechanical fastener that has threads to hold objects together or grip materials. Common threaded fasteners include screws, nuts, and bolts.

threads

A long, spiral ridge around the exterior or interior of a cylindrical part. Threads are found on screws and other types of fasteners.

torque

A force that causes rotation. Torque is required to tighten a bolt, screw, or nut.

ultraviolet

UV. A potentially harmful wavelength of light that is below, or shorter than, violet on the light spectrum. Ultraviolet light can be harmful for human operators.

weld defects

An irregularity in the specified and expected composition of a weld that exceeds the part design's tolerances. A defect is an unacceptable discontinuity.

weld metal

The molten metal that becomes the welded joint upon solidification. Weld metal is composed of base metals and filler metal.

welding

The joining of two or more materials using heat, pressure, or a combination of energy sources. Welding forms a permanent joint.

workholding devices

A component used to hold and locate a workpiece. Workholding devices include jigs and clamps.

Workstations

A specific area of an assembly site that is designated for performing specific tasks or work duties. Workstations are organized to increase the efficiency of an assembly site.

wrenches

A tool used for fastening nuts and bolts. Wrenches contain fixed or moving jaws or a round attachment that grips nuts or bolts.