Structural and Operational Complexity of Manual Assembly Systems

Al‐Zuheri, Atiya

doi:10.3844/jcssp.2013.1822.1829

Cited by 7 publications

(5 citation statements)

References 39 publications

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“…Chryssolouris et al [34] linked manufacturing complexity to quantity of machines, products, processes and resources needed. Similarly, Al-Zuheri [35] measured assembly complexity through operating times,…”

Section: System-centred Approachmentioning

confidence: 99%

Empirical comparison of assembly complexity assessment approaches in manufacturing

Capponi¹,

Mastrogiacomo²,

Franceschini

2023

Preprint

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Investigating assembly complexity is a continuing concern within manufacturing field, as it may impact quality and costs of products. There is a growing body of literature aimed at developing novel and reliable methods to assess assembly complexity. The first aim of this paper is to provide an extensive literature review, identifying the main approaches to this problem. Three main approaches emerged: product-centred approach, information-centred approach and system-centred approach. A second goal is to carry out a comparative analysis of these approaches highlighting their advantages, limitations and providing guidance for process and product designers seeking to control assembly complexity. For each approach, a representative method was chosen, analysed in detail, and applied to three different real products.

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Section: System-centred Approachmentioning

confidence: 99%

Empirical comparison of assembly complexity assessment approaches in manufacturing

Capponi¹,

Mastrogiacomo²,

Franceschini

2023

Preprint

View full text Add to dashboard Cite

show abstract

“…In some studies, the complexity perceived by the operators was investigated in search for a better understanding of how the complexity can be managed (Hong et al, 2007;Mattsson et al, 2016;Al-Zuheri, 2013;Alkan et al, 2016). Krugh et al presented a framework for enumerating assembly variables in a fully manual automotive assembly process correlated with the potential for quality defect based on the design, process and human factors.…”

Section: Literature Reviewmentioning

confidence: 99%

Quantifying the complexity of subassemblies in a fully automated assembly system

Gao

Zheng

et al. 2019

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Purpose Complexity is the main challenge for present and future manufacturers. Assembly complexity heavily affects a product’s final quality in the fully automated assembly system. This paper aims to propose a new method to assess the complexity of modern automated assembly system at the assembly design stage with respect to the characteristics of both manufacturing system and each single component to be mounted. Aiming at validating the predictive model, a regression model is additionally presented to estimate the statistic relationship between the real assembly defect rate and predicted complexity of the fully automated assembly system. Design/methodology/approach The research herein extends the S. N. Samy and H. A. ElMaraghy’s model and seeks to redefine the predictive model using fuzzy evaluation against a fully automated assembly process at the assembly design stages. As the evaluation based on the deterministic scale with accurate crisp number can hardly reflect the uncertainty of the judgement, fuzzy linguistic variables are used to measure the interaction among influence factors. A dependency matrix is proposed to estimate the assembly complexity with respect to the interactions between mechanic design, electric design and process factors and main functions of assembly system. Furthermore, a complexity attributes matrix of single part is presented, to map the relationship between all individual parts to be mounted and three major factors mentioned in the dependency matrix. Findings The new proposed model presents a formal quantification to predict assembly complexity. It clarifies that how the attributes of assembly system and product components complicate the assembly process and in turn influence the manufacturing performance. A center bolt valve in the camshaft of continue variable valve timing is used to demonstrate the application of the developed methodology in this study. Originality/value This paper presents a developed method, which can be used to improve the design solution of assembly concept and optimize the process flow with the least complexity.

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“…As the total amount of work increases at a station, so does the variance in operation time at that station. The skill level of workers also has an effect on the resulting complexity in the system, because each worker will complete tasks in a different amount of time [21]. These aspects all contribute to the variation in task completion time.…”

Section: Assembly System Impact Factors and Decisionsmentioning

confidence: 99%

“…The product-process matrix uses volume and variety for determining process structure [18]. Similarly, in assembly the volume and variety affect the type of assembly system that is appropriate [21]. As the volume increases and the variety decreases, automation is more appropriate.…”

Section: Volume and Varietymentioning

confidence: 99%

Strategic Framework for Manual Assembly System Design

Vallandingham

Strandhagen

Alfnes

et al. 2018

Lecture Notes in Electrical Engineering

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Manual assembly is necessary for production of many products today, as products are becoming more complex and customer specific. Manual assembly systems are important for competitiveness and are therefore a strategic issue. Previous literature has looked at specific problems, such as line balancing, although a strategic perspective is required to effectively fulfil market requirements. Before designing a manual assembly system, it is important to consider the different impact factors to find the ideal manual assembly system configuration. This study discusses the different impact factors and decisions in strategic manual assembly system design. The purpose of this paper is to develop a framework to assist in strategic design of manual assembly systems. Testing the framework in a case company shows that by designing the manual assembly system according to the identified impact factors, significant reductions of throughput time and non-value adding time in manual assembly can be achieved.

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Structural and Operational Complexity of Manual Assembly Systems

Cited by 7 publications

References 39 publications

Empirical comparison of assembly complexity assessment approaches in manufacturing

Empirical comparison of assembly complexity assessment approaches in manufacturing

Quantifying the complexity of subassemblies in a fully automated assembly system

Strategic Framework for Manual Assembly System Design

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