Machining centers are adjusted for accuracy by an assembly worker. The assembly time therefore varies with the worker, and the variations are a source of loss. An attempt was made to use virtual parameter design to reduce this loss. The appropriateness of virtual design was tested and confirmed by comparing the results of assembly of actual machining centers with the S/N gain under the initial and confirmation conditions in virtual design. As a result of this study, virtual design clearly showed the differences among workers’ assembly skills, and had the further effect of suggesting ways of designing the work process to mask the skill differences. It also became clear from this study that as measured by the loss function, the differences among workers’ skill levels exceeded ten million yen.
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