Natalia Svensson Harari
Natalia Svensson Harari is a Ph.D. candidate in Innova-tion and Design at the School of InnovaInnova-tion, Design and Engineering at Mälardalen University in Sweden within the research specialisation Innovation and Product Realisation. She is part of the Industrial Research School of Innovative Manufacturing Development (INNOFACTURE). Natalia is an industrial production engineer and also holds a M.Sc. in Production Engineering and Management from The Royal Institute of Technology (KTH). She has several years of ex-perience in research, production development, and training activities from Volvo CE and internationally in different branches of the industry.
ri W O RK IN G P RO C ED U RE S I N D ES IG N P RO C ES SE S T O A C H IE V E F LE X IB LE A SS EM BL Y S YS TE M S 2020 ISBN 978-91-7485-488-6 Address: P.O. Box 883, SE-721 23 Västerås. Sweden
Address: P.O. Box 325, SE-631 05 Eskilstuna. Sweden
The purpose of the research presented in this thesis is to increase knowledge on how to achieve flexible assembly systems through design processes. The research objective is thus to contribute to the development of working procedures to support design processes of flexible assembly systems. Factors involved in design processes of flexible assembly systems and their influence on the design process to achieve flexible assembly systems have been studied by literature reviews and a series of five case studies conducted in the manufacturing industry of heavy vehicles. This thesis has appended six papers presenting the results of these studies.
The findings of this research are integrated in a developed flexibility-oriented design process framework. The framework places strong emphasis on consider-ing flexibility durconsider-ing the early innovative phases of technology development to enable timely changes and adaptations of both products and assembly systems designs with a holistic long-term view. To this end, the framework encourages the inclusion of diverse processes, roles, and functions within an organisation in the design process, and highlights activities that facilitate the design of flexible assembly systems. As such, it can be used to support the work of those involved in designing flexible assembly systems.
Mälardalen University Press Dissertations No. 328
WORKING PROCEDURES IN DESIGN PROCESSES
TO ACHIEVE FLEXIBLE ASSEMBLY SYSTEMS
Natalia Svensson Harari 2020
School of Innovation, Design and Engineering
Mälardalen University Press Dissertations No. 328
WORKING PROCEDURES IN DESIGN PROCESSES
TO ACHIEVE FLEXIBLE ASSEMBLY SYSTEMS
Natalia Svensson Harari 2020
Copyright © Natalia Svensson Harari, 2020 ISBN 978-91-7485-488-6
ISSN 1651-4238
Printed by E-Print AB, Stockholm Sweden
Copyright © Natalia Svensson Harari, 2020 ISBN 978-91-7485-488-6
ISSN 1651-4238
Mälardalen University Press Dissertations No. 328
WORKING PROCEDURES IN DESIGN PROCESSES TO ACHIEVE FLEXIBLE ASSEMBLY SYSTEMS
Natalia Svensson Harari
Akademisk avhandling
som för avläggande av teknologie doktorsexamen i innovation och design vid Akademin för innovation, design och teknik kommer att offentligen försvaras fredagen den 11 december 2020, 14.00 i A2-035 +(Digitalt Zoom), Mälardalens högskola, Eskilstuna.
Fakultetsopponent: Professor Chris McMahon, University of Bristol
Akademin för innovation, design och teknik
Mälardalen University Press Dissertations No. 328
WORKING PROCEDURES IN DESIGN PROCESSES TO ACHIEVE FLEXIBLE ASSEMBLY SYSTEMS
Natalia Svensson Harari
Akademisk avhandling
som för avläggande av teknologie doktorsexamen i innovation och design vid Akademin för innovation, design och teknik kommer att offentligen försvaras fredagen den 11 december 2020, 14.00 i A2-035 +(Digitalt Zoom), Mälardalens högskola, Eskilstuna.
Fakultetsopponent: Professor Chris McMahon, University of Bristol
Abstract
Designing is becoming increasingly complex. Manufacturers strive achieving flexible assembly systems that can easily accommodate diverse product offerings while transitioning towards new (radical) products, integrating new manufacturing technologies and providing specific customer solutions. However, designing flexibility is a challenge. There are several flexibility dimensions and perspectives as well as a need for design support to achieve it in a long term.
A design process concerns the way of working (how) to generate an assembly system solution before its realisation. Thus, it is crucial to establish preconditions for the development of assembly systems. A single design process does not fit all the design problems, so already during the design process, changes in assembly systems by means of flexibility should be further investigated. The purpose of the research is to increase knowledge on how to achieve flexible assembly systems through design processes with the objective to contribute to the development of working procedures to support design processes of flexible assembly systems.
Factors involved in the design process of flexible assembly systems and their influence in the design process to achieve flexible assembly systems have been studied based on literature reviews and five case studies conducted in the manufacturing industry of heavy vehicles. The thesis is based on six appended papers.
A framework has been developed which integrates the findings of the research. It highlights the need of working in early phases of technology development to address timely changes and adaptations in both products and assembly systems designs. Thus, showing the importance of involving different processes as well as roles and functions within an organisation. Furthermore, it shed lights on activities that could facilitate the design process of flexible assembly systems in a long term. These working procedures are meant to support those involved in the design process of flexible assembly systems.
ISBN 978-91-7485-488-6 ISSN 1651-4238
Abstract
Designing is becoming increasingly complex. Manufacturers strive achieving flexible assembly systems that can easily accommodate diverse product offerings while transitioning towards new (radical) products, integrating new manufacturing technologies and providing specific customer solutions. However, designing flexibility is a challenge. There are several flexibility dimensions and perspectives as well as a need for design support to achieve it in a long term.
A design process concerns the way of working (how) to generate an assembly system solution before its realisation. Thus, it is crucial to establish preconditions for the development of assembly systems. A single design process does not fit all the design problems, so already during the design process, changes in assembly systems by means of flexibility should be further investigated. The purpose of the research is to increase knowledge on how to achieve flexible assembly systems through design processes with the objective to contribute to the development of working procedures to support design processes of flexible assembly systems.
Factors involved in the design process of flexible assembly systems and their influence in the design process to achieve flexible assembly systems have been studied based on literature reviews and five case studies conducted in the manufacturing industry of heavy vehicles. The thesis is based on six appended papers.
A framework has been developed which integrates the findings of the research. It highlights the need of working in early phases of technology development to address timely changes and adaptations in both products and assembly systems designs. Thus, showing the importance of involving different processes as well as roles and functions within an organisation. Furthermore, it shed lights on activities that could facilitate the design process of flexible assembly systems in a long term. These working procedures are meant to support those involved in the design process of flexible assembly systems.
ISBN 978-91-7485-488-6 ISSN 1651-4238
Abstract
Designing is becoming increasingly complex. Manufacturers strive achieving flexible assembly systems that can easily accommodate diverse product offerings while transitioning towards new (radical) products, integrating new manufacturing technologies and providing specific customer solutions. However, designing flexibility is a challenge. There are several flexibility dimensions and perspectives as well as a need for design support to achieve it in a long term.
A design process concerns the way of working (how) to generate an assembly system solution before its realisation. Thus, it is crucial to establish preconditions for the development of assembly systems. A single design process does not fit all the design problems, so already during the design process, changes in assembly systems by means of flexibility should be further investigated. The purpose of the research is to increase knowledge on how to achieve flexible assembly systems through design processes with the objective to contribute to the development of working procedures to support design processes of flexible assembly systems.
Factors involved in the design process of flexible assembly systems and their influence in the design process to achieve flexible assembly systems have been studied based on literature reviews and five case studies conducted in the manufacturing industry of heavy vehicles. The thesis is based on six appended papers.
A framework has been developed which integrates the findings of the research. It highlights the need of working in early phases of technology development to address timely changes and adaptations in both products and assembly systems designs. Thus, showing the importance of involving different processes as well as roles and functions within an organisation. Furthermore, it shed lights on activities that could facilitate the design process of flexible assembly systems in a long term. These working procedures are meant to support those involved in the design process of flexible assembly systems.
Abstract
Designing is becoming increasingly complex. Manufacturers strive achieving flexible assembly systems that can easily accommodate diverse product offerings while transitioning towards new (radical) products, integrating new manufacturing technologies and providing specific customer solutions. However, designing flexibility is a challenge. There are several flexibility dimensions and perspectives as well as a need for design support to achieve it in a long term.
A design process concerns the way of working (how) to generate an assembly system solution before its realisation. Thus, it is crucial to establish preconditions for the development of assembly systems. A single design process does not fit all the design problems, so already during the design process, changes in assembly systems by means of flexibility should be further investigated. The purpose of the research is to increase knowledge on how to achieve flexible assembly systems through design processes with the objective to contribute to the development of working procedures to support design processes of flexible assembly systems.
Factors involved in the design process of flexible assembly systems and their influence in the design process to achieve flexible assembly systems have been studied based on literature reviews and five case studies conducted in the manufacturing industry of heavy vehicles. The thesis is based on six appended papers.
A framework has been developed which integrates the findings of the research. It highlights the need of working in early phases of technology development to address timely changes and adaptations in both products and assembly systems designs. Thus, showing the importance of involving different processes as well as roles and functions within an organisation. Furthermore, it shed lights on activities that could facilitate the design process of flexible assembly systems in a long term. These working procedures are meant to support those involved in the design process of flexible assembly systems.
Sammanfattning
Designprocesser har blivit allt mer komplexa. Tillverkare strävar efter att uppnå flexibla monteringssystem som lättare kan hantera en mångfald av produkterbjudanden medan verksamheten samtidigt övergår till nya (radikala) produkter, integrerar nya tillverkningsteknologier och erbjuder flera kundspecifika lösningar. Att designa för flexibilitet är likväl en utmaning och det krävs framförallt flera flexibilitetsdimensioner och perspektiv liksom behov av designstöd för att uppnå flexibilitet på lång sikt. En designprocess berör sättet att arbeta (hur) för att generera en monteringssystemslösning innan dess implementering. Därför är det centralt att skapa förutsättningar för utvecklingen av monteringssystem. En designprocess passar inte alla designproblem och därmed borde förändringar i monteringssystem genom flexibilitet undersökas ytterligare redan under designprocessen. Syftet med forskningen är därför att öka kunskapen om hur man kan uppnå flexibla monteringssystem genom designprocesser med målet att bidra till utvecklingen av arbetssätt som stödjer designprocesser för skapandet av flexibla monteringssystem.
Faktorer i designprocessen för flexibla monteringssystem och deras påverkan i designprocessen för att uppnå flexibla monteringssystem har studerats baserat på litteraturgenomgångar och fem fallstudier genomförda i tillverkningsindustrin för tunga fordon. Avhandlingen är baserad på sex bifogade artiklar.
Ett ramverk har utvecklats som integrerar resultaten från forskningen. Ramverket åskådliggör behovet av att arbeta i tidiga faser av teknikutvecklingen för att adressera förändringar och anpassningar i rätt tid med avseende på både produkter och monteringssystemets design. Därigenom visas vikten av att involvera olika processer liksom roller och funktioner i en organisation. Dessutom belyser ramverket även aktiviteter som skulle kunna underlätta designprocessen för att uppnå flexibla monteringssystem på lång sikt. Dessa arbetssätt är avsedda att stödja de som är involverade i designprocessen av flexibla monteringssystem.
Sammanfattning
Designprocesser har blivit allt mer komplexa. Tillverkare strävar efter att uppnå flexibla monteringssystem som lättare kan hantera en mångfald av produkterbjudanden medan verksamheten samtidigt övergår till nya (radikala) produkter, integrerar nya tillverkningsteknologier och erbjuder flera kundspecifika lösningar. Att designa för flexibilitet är likväl en utmaning och det krävs framförallt flera flexibilitetsdimensioner och perspektiv liksom behov av designstöd för att uppnå flexibilitet på lång sikt. En designprocess berör sättet att arbeta (hur) för att generera en monteringssystemslösning innan dess implementering. Därför är det centralt att skapa förutsättningar för utvecklingen av monteringssystem. En designprocess passar inte alla designproblem och därmed borde förändringar i monteringssystem genom flexibilitet undersökas ytterligare redan under designprocessen. Syftet med forskningen är därför att öka kunskapen om hur man kan uppnå flexibla monteringssystem genom designprocesser med målet att bidra till utvecklingen av arbetssätt som stödjer designprocesser för skapandet av flexibla monteringssystem.
Faktorer i designprocessen för flexibla monteringssystem och deras påverkan i designprocessen för att uppnå flexibla monteringssystem har studerats baserat på litteraturgenomgångar och fem fallstudier genomförda i tillverkningsindustrin för tunga fordon. Avhandlingen är baserad på sex bifogade artiklar.
Ett ramverk har utvecklats som integrerar resultaten från forskningen. Ramverket åskådliggör behovet av att arbeta i tidiga faser av teknikutvecklingen för att adressera förändringar och anpassningar i rätt tid med avseende på både produkter och monteringssystemets design. Därigenom visas vikten av att involvera olika processer liksom roller och funktioner i en organisation. Dessutom belyser ramverket även aktiviteter som skulle kunna underlätta designprocessen för att uppnå flexibla monteringssystem på lång sikt. Dessa arbetssätt är avsedda att stödja de som är involverade i designprocessen av flexibla monteringssystem.
Acknowledgements
Many people contributed to this thesis in various ways and deserve my gratitude. I would particularly like to acknowledge:
My supervisors, Professor Anders Fundin, Dr Anna-Lena Carlsson, Hans Wikstrand and Dr Anna Ericson Öberg for supporting me throughout this research process and offering different but complementary perspectives to help me progress towards completion. I also thank Associate Professor Paolo Frumento, from the University of Pisa, Italy, for your collaboration and support in particular concerning statistics.
My colleagues at Mälardalen University, IDT, and the Innofacture Research School who have supported me in one way or another. In particular, I thank Peter E Johansson, Glenn Johansson, Anna Granlund, Anders Berglund, Anders Hellström, and the Innofacture fellows.
Lasse Frank for the support with the cover of this thesis and Kajsa Franck for the design of the cover of this thesis.
Thanks also to Volvo CE and everyone at the different factories who participated and allowed me to conduct my research.
My greatest thanks go to my family. Mom and dad, my siblings, my parents in law, thank you for your support and being there for us. My beloved husband and our beloved daughter, you both have accompanied this process unconditionally, without you this would not have been possible. Finally, this research work was funded by the Knowledge Foundation within the framework of the INNOFACTURE Research School, the participating companies, and Mälardalen University, Sweden. The research work is also part of the initiative for Excellence in Production Research (XPRES) which is a joint project between Mälardalen University, the Royal Institute of Technology, and Swerea. XPRES is one of two governmentally funded Swedish strategic initiatives for research excellence in Production Engineering.
Natalia
Brussels, October 2020
Acknowledgements
Many people contributed to this thesis in various ways and deserve my gratitude. I would particularly like to acknowledge:
My supervisors, Professor Anders Fundin, Dr Anna-Lena Carlsson, Hans Wikstrand and Dr Anna Ericson Öberg for supporting me throughout this research process and offering different but complementary perspectives to help me progress towards completion. I also thank Associate Professor Paolo Frumento, from the University of Pisa, Italy, for your collaboration and support in particular concerning statistics.
My colleagues at Mälardalen University, IDT, and the Innofacture Research School who have supported me in one way or another. In particular, I thank Peter E Johansson, Glenn Johansson, Anna Granlund, Anders Berglund, Anders Hellström, and the Innofacture fellows.
Lasse Frank for the support with the cover of this thesis and Kajsa Franck for the design of the cover of this thesis.
Thanks also to Volvo CE and everyone at the different factories who participated and allowed me to conduct my research.
My greatest thanks go to my family. Mom and dad, my siblings, my parents in law, thank you for your support and being there for us. My beloved husband and our beloved daughter, you both have accompanied this process unconditionally, without you this would not have been possible. Finally, this research work was funded by the Knowledge Foundation within the framework of the INNOFACTURE Research School, the participating companies, and Mälardalen University, Sweden. The research work is also part of the initiative for Excellence in Production Research (XPRES) which is a joint project between Mälardalen University, the Royal Institute of Technology, and Swerea. XPRES is one of two governmentally funded Swedish strategic initiatives for research excellence in Production Engineering.
Natalia
Publications
The following papers are appended to this thesis and are referred to in the text by their Roman numerals.
I Svensson Harari, N., Osterman, C., Bruch, J., Jackson, M. (2014) Flexibility in lean mixed model assembly lines. Advances in Production Management Systems Conference, APMS
2014, Ajaccio, France.
Contribution: Svensson Harari initiated and wrote most of the paper together with Osterman. Bruch and Jackson helped improve the structure and readability of the paper. Svensson Harari presented the paper.
II Svensson Harari, N., Bruch, J., Jackson, M. (2014) Mixed-product assembly line: characteristics and design challenges. 6th Swedish Production Symposium, SPS14,
Gothenburg, Sweden.
Contribution: The authors initiated the paper together. Svensson Harari and Jackson wrote the paper together. Bruch provided support by offering ideas about the paper’s content and structure. Svensson Harari presented the paper.
III Svensson Harari, N., Fundin, A., Carlsson A-L. (2018) Components of the design process of flexible and reconfigurable assembly systems. Procedia Manufacturing, Vol. 25, pp. 549-556.
Contribution: Svensson Harari initiated and wrote the paper. Fundin and Carlsson helped improve the paper’s structure and readability. Svensson Harari presented the paper at the 8th Swedish Production Symposium, SPS18, Stockholm, Sweden.
IV Svensson Harari, N., Fundin, A., Carlsson A-L. (2020) A participatory research approach for studying the design process of flexible assembly systems. Procedia CIRP, Vol. 93, pp.1043-1048
Contribution: Svensson Harari initiated and wrote the paper. Fundin and Carlsson supported with structure and readability of the paper. Svensson Harari presented the paper at the 53rd CIRP Conference on Manufacturing Systems 2020.
V Svensson Harari, N., Fundin, A., Frumento, P. (2020) Investigating the design process and flexibility in the assembly system of an automotive firm: inputs to flexible assembly systems designs. Submitted for review to a journal.
Contribution: Svensson Harari initiated and wrote the paper. Fundin and Frumento supported with structure and readability of the paper.
VI Svensson Harari, N and Fundin A. (2020) An early-phase design process to enable long-term flexibility in assembly systems. Submitted for second review to a journal.
Contribution: Svensson Harari initiated and wrote the paper. Fundin supported with structure and readability of the paper.
Publications
The following papers are appended to this thesis and are referred to in the text by their Roman numerals.
I Svensson Harari, N., Osterman, C., Bruch, J., Jackson, M. (2014) Flexibility in lean mixed model assembly lines. Advances in Production Management Systems Conference, APMS
2014, Ajaccio, France.
Contribution: Svensson Harari initiated and wrote most of the paper together with Osterman. Bruch and Jackson helped improve the structure and readability of the paper. Svensson Harari presented the paper.
II Svensson Harari, N., Bruch, J., Jackson, M. (2014) Mixed-product assembly line: characteristics and design challenges. 6th Swedish Production Symposium, SPS14,
Gothenburg, Sweden.
Contribution: The authors initiated the paper together. Svensson Harari and Jackson wrote the paper together. Bruch provided support by offering ideas about the paper’s content and structure. Svensson Harari presented the paper.
III Svensson Harari, N., Fundin, A., Carlsson A-L. (2018) Components of the design process of flexible and reconfigurable assembly systems. Procedia Manufacturing, Vol. 25, pp. 549-556.
Contribution: Svensson Harari initiated and wrote the paper. Fundin and Carlsson helped improve the paper’s structure and readability. Svensson Harari presented the paper at the 8th Swedish Production Symposium, SPS18, Stockholm, Sweden.
IV Svensson Harari, N., Fundin, A., Carlsson A-L. (2020) A participatory research approach for studying the design process of flexible assembly systems. Procedia CIRP, Vol. 93, pp.1043-1048
Contribution: Svensson Harari initiated and wrote the paper. Fundin and Carlsson supported with structure and readability of the paper. Svensson Harari presented the paper at the 53rd CIRP Conference on Manufacturing Systems 2020.
V Svensson Harari, N., Fundin, A., Frumento, P. (2020) Investigating the design process and flexibility in the assembly system of an automotive firm: inputs to flexible assembly systems designs. Submitted for review to a journal.
Contribution: Svensson Harari initiated and wrote the paper. Fundin and Frumento supported with structure and readability of the paper.
VI Svensson Harari, N and Fundin A. (2020) An early-phase design process to enable long-term flexibility in assembly systems. Submitted for second review to a journal.
Contribution: Svensson Harari initiated and wrote the paper. Fundin supported with structure and readability of the paper.
Additional publications
The author also contributed to the following publications which are not included in this thesis:
Mattsson, S., Tarrar, M., & Svensson Harari, N. (2020). Using the compleXity index for improvement work: investigating utilisation in an automotive company. International Journal of
Manufacturing Research, 15(1), 3-21.
Schedin, J., Svensson Harari, N., Jackson, M., Deleryd, M. (2016). Management of newness in an assembly system, Journal of Machine Engineering, 16(1), 92-108.
Tarrar, M., Svensson Harari, N., Mattsson, S. (2016). Using the compleXity index to discuss improvements at work: A case study in an automotive company. Proceedings of the 7th Swedish
Production Symposium. Lund, Sweden.
Svensson Harari, N. (2015). Design process of flexible assembly systems. Licentiate Thesis.
Mälardalen University, Sweden.
Osterman, C., Svensson Harari, N., Fundin, A. (2014). Examination of the flexibility paradox in a Lean system. 58th EOQ conference, Gothenburg, Sweden.
Svensson Harari, N., Bruch, J., Jackson, M. (2013). Flexibility needs and enablers in assembly
systems. Proceedings of ICPR, 22nd International Conference on Production Research, Iguassu Falls, Brazil.
Additional publications
The author also contributed to the following publications which are not included in this thesis:
Mattsson, S., Tarrar, M., & Svensson Harari, N. (2020). Using the compleXity index for improvement work: investigating utilisation in an automotive company. International Journal of
Manufacturing Research, 15(1), 3-21.
Schedin, J., Svensson Harari, N., Jackson, M., Deleryd, M. (2016). Management of newness in an assembly system, Journal of Machine Engineering, 16(1), 92-108.
Tarrar, M., Svensson Harari, N., Mattsson, S. (2016). Using the compleXity index to discuss improvements at work: A case study in an automotive company. Proceedings of the 7th Swedish
Production Symposium. Lund, Sweden.
Svensson Harari, N. (2015). Design process of flexible assembly systems. Licentiate Thesis.
Mälardalen University, Sweden.
Osterman, C., Svensson Harari, N., Fundin, A. (2014). Examination of the flexibility paradox in a Lean system. 58th EOQ conference, Gothenburg, Sweden.
Svensson Harari, N., Bruch, J., Jackson, M. (2013). Flexibility needs and enablers in assembly
systems. Proceedings of ICPR, 22nd International Conference on Production Research, Iguassu Falls, Brazil.
Table of contents
Abstract ... i
Sammanfattning ...iii
Acknowledgements ... v
Publications ... vii
Additional publications ...ix
Table of contents ... xi
1. Introduction ... 13
1.1 Design processes, change, and flexibility ... 13
1.2 Problem description ... 14
1.3 Objective and research questions... 18
1.4 Scope and delimitations ... 18
1.5 Outline of the thesis ... 19
2. Theoretical framework ... 21
2.1 Design processes of assembly systems ... 21
2.2 Flexible assembly systems ... 23
2.3 Design processes for flexible assembly systems ... 29
2.4 General synthesis of the theoretical framework ... 32
3. Research methodology ... 37
3.1 Research approach ... 37
3.2 Research design ... 38
3.3 Research quality ... 43
4. Summary of the appended papers ... 47
4.1 Paper I – Flexibility in lean mixed model assembly lines ... 47
4.2 Paper II – MPAL: Characteristics and design challenges ... 48
4.3 Paper III – Components of the design process ... 50
4.4 Paper IV – A participatory research approach ... 53
4.5 Paper V – Investigating the design process and flexibility ... 56
4.6 Paper VI – An early-phase design process ... 58
5. Analysis... 61
5.1 Factors involved in design processes of flexible assembly systems ... 61
5.2 Influence of the identified factors ... 64
6. Working procedures in design processes for flexible assembly systems ... 69
6.1 A flexibility – oriented design process framework ... 69
6.2 Theoretical contributions and practical implications... 74
7. Conclusion and future research ... 77
7.1 General conclusions ... 77
7.2 Research method discussion ... 77
7.3 Future research ... 77 References ... 79
Table of contents
Abstract ... i Sammanfattning ...iii Acknowledgements ... v Publications ... viiAdditional publications ...ix
Table of contents ... xi
1. Introduction ... 13
1.1 Design processes, change, and flexibility ... 13
1.2 Problem description ... 14
1.3 Objective and research questions... 18
1.4 Scope and delimitations ... 18
1.5 Outline of the thesis ... 19
2. Theoretical framework ... 21
2.1 Design processes of assembly systems ... 21
2.2 Flexible assembly systems ... 23
2.3 Design processes for flexible assembly systems ... 29
2.4 General synthesis of the theoretical framework ... 32
3. Research methodology ... 37
3.1 Research approach ... 37
3.2 Research design ... 38
3.3 Research quality ... 43
4. Summary of the appended papers ... 47
4.1 Paper I – Flexibility in lean mixed model assembly lines ... 47
4.2 Paper II – MPAL: Characteristics and design challenges ... 48
4.3 Paper III – Components of the design process ... 50
4.4 Paper IV – A participatory research approach ... 53
4.5 Paper V – Investigating the design process and flexibility ... 56
4.6 Paper VI – An early-phase design process ... 58
5. Analysis... 61
5.1 Factors involved in design processes of flexible assembly systems ... 61
5.2 Influence of the identified factors ... 64
6. Working procedures in design processes for flexible assembly systems ... 69
6.1 A flexibility – oriented design process framework ... 69
6.2 Theoretical contributions and practical implications... 74
7. Conclusion and future research ... 77
7.1 General conclusions ... 77
7.2 Research method discussion ... 77
7.3 Future research ... 77
1. Introduction
This chapter presents the background relevant to the research and outlines the research problem, the objective, and the research questions. It concludes by stating the scope and delimitations of the research.
1.1 Design processes, change, and flexibility
Designing is becoming increasingly complex because of dynamic technological, environmental, societal and market changes whose influence and dependence on engineering design is rarely articulated (Eckert et al., 2019). Additionally, new production paradigms associated with Industry 4.0 such as mass customisation and personalisation of production require the introduction of new manufacturing technologies that are expected to massively increase flexibility (Davies, 2015). Therefore, manufacturing industries are moving towards more digitalised, reconfigurable, and flexible production processes (ElMaraghy, 2019). In addition, the threat of climate change necessitates a great increase in sustainability, in both the transportation sector and society as a whole. For these reasons and others, there have been discussions concerning potential disruptions of the transport sector and society driven by the combined impact of innovations such as electromobility, shared mobility, connectivity, and automation (Sprei, 2018). Despite the increasing availability and competitiveness of electric vehicles, whose powertrains differ radically from those of conventional vehicles, the speed of transformation of the transport sector is uncertain. However, forecasts suggest that the internal combustion engine will remain relevant beyond 2030 (Springer India-New, 2016). Flexibility is both an objective and a challenge for manufacturing firms undergoing transitions such as the movement towards electromobility (Köhl et al., 2018, Bichler et al., 2018). Manufacturers must therefore develop production systems that can readily accommodate diverse product offers while transitioning towards new (radical) products, integrating new manufacturing technologies, and providing customer-specific solutions.
Mastery of development has long been considered a source of competitive advantage (Wheelwright and Clark, 1992, p.1). Design processes are fundamental in the development of assembly systems, which are crucial to the success of manufacturing firms. A design process is a way of doing design work (O’Donovan et al., 2005, p. 62), encompassing both working practices and procedures that guide the design work such that an assembly system solution is generated in a way that allows its subsequent implementation and use in the manufacture of specific products. The pursuit of novel solutions is a core characteristic of design processes (O’Donovan et al., 2005), so change is an inherent part of design (Jarratt et al., 2005) and one of its most powerful driving factors (Eckert et al., 2004). It has been noted that firms seek to enhance their competitiveness through process innovation (Von Krogh et al., 2018), including (how) by redesigning operating processes to improve efficiency and effectiveness (Sawhney et al., 2006, p. 78). Production development plays a central role in such efforts and thus needs further study (Kurkkio et al., 2011,
1. Introduction
This chapter presents the background relevant to the research and outlines the research problem, the objective, and the research questions. It concludes by stating the scope and delimitations of the research.
1.1 Design processes, change, and flexibility
Designing is becoming increasingly complex because of dynamic technological, environmental, societal and market changes whose influence and dependence on engineering design is rarely articulated (Eckert et al., 2019). Additionally, new production paradigms associated with Industry 4.0 such as mass customisation and personalisation of production require the introduction of new manufacturing technologies that are expected to massively increase flexibility (Davies, 2015). Therefore, manufacturing industries are moving towards more digitalised, reconfigurable, and flexible production processes (ElMaraghy, 2019). In addition, the threat of climate change necessitates a great increase in sustainability, in both the transportation sector and society as a whole. For these reasons and others, there have been discussions concerning potential disruptions of the transport sector and society driven by the combined impact of innovations such as electromobility, shared mobility, connectivity, and automation (Sprei, 2018). Despite the increasing availability and competitiveness of electric vehicles, whose powertrains differ radically from those of conventional vehicles, the speed of transformation of the transport sector is uncertain. However, forecasts suggest that the internal combustion engine will remain relevant beyond 2030 (Springer India-New, 2016). Flexibility is both an objective and a challenge for manufacturing firms undergoing transitions such as the movement towards electromobility (Köhl et al., 2018, Bichler et al., 2018). Manufacturers must therefore develop production systems that can readily accommodate diverse product offers while transitioning towards new (radical) products, integrating new manufacturing technologies, and providing customer-specific solutions.
Mastery of development has long been considered a source of competitive advantage (Wheelwright and Clark, 1992, p.1). Design processes are fundamental in the development of assembly systems, which are crucial to the success of manufacturing firms. A design process is a way of doing design work (O’Donovan et al., 2005, p. 62), encompassing both working practices and procedures that guide the design work such that an assembly system solution is generated in a way that allows its subsequent implementation and use in the manufacture of specific products. The pursuit of novel solutions is a core characteristic of design processes (O’Donovan et al., 2005), so change is an inherent part of design (Jarratt et al., 2005) and one of its most powerful driving factors (Eckert et al., 2004). It has been noted that firms seek to enhance their competitiveness through process innovation (Von Krogh et al., 2018), including (how) by redesigning operating processes to improve efficiency and effectiveness (Sawhney et al., 2006, p. 78). Production development plays a central role in such efforts and thus needs further study (Kurkkio et al., 2011,
Lager et al., 2010). In particular, research and innovative solutions for production systems are needed to help firms respond to market evolutions (Fratini et al., 2020). Research on design and development processes is thus needed to meet current challenges (Wynn et al., 2019).
The ability to design changes is essential for the survival and prosperity of manufacturing firms (ElMaraghy and Wiendahl, 2009). Equally important is the ability to design systems that can adapt to changes. To accommodate shortened product and process life cycles (Wiendahl et al., 2007), assembly systems should be designed for change (Hu et al., 2011) and frequent product variation (Heilala and Voho, 2001). That is to say, factories and manufacturing technologies should be capable of producing both current and future product generations (ElMaraghy and Wiendahl, 2009). According to Ross et al. (2008), designing changeable systems with such capabilities increases the value delivered over a system’s lifecycle. Changeability is an umbrella concept encompassing multiple paradigms relating to the ability to handle variation, one of which is flexibility (ElMaraghy and Wiendahl, 2009). Flexibility refers to the ability to cope with changes in different dimensions without incurring significant transition penalties or adversely affecting performance outcomes (Koste and Malhotra, 1999).Because of the importance of flexibility, the capacity for change should be considered during the process of assembly system design. However, designing flexible systems remains challenging.
1.2 Problem description
No single design process will be suitable for all design problems, and the complexity of design processes prevents their comprehensive description using a single model (Wynn and Clarkson, 2018). Therefore, design processes, despite showing common patterns, should be structured to deliver an expected product (Gedenryd, 1998); in the context of this research, the expected product is a flexible assembly system. The following section elaborates the research problem by examining the nature of design processes and flexible assembly systems, before outlining the challenges arising from the relationship between design processes and assembly system flexibility.
1.2.1 Design processes
Engineering design processes are means to generate design solutions that can be implemented successfully. In industrial firms, design processes are conducted within the context of projects (Karlsson et al., 2009). To conduct a project within a firm, those involved must secure a budget and the necessary resources, and complete their work within a set deadline. Engineering design projects have additional specific requirements. Managers of design engineering projects must effectively oversee and guide the work of the design team and its output, as well as the factors influencing the design team (Hales and Gooch, 2004). Design processes are fundamental to engineering design projects. These processes can be divided into distinct phases, each associated with specific activities/tasks, and are sensitive to
Lager et al., 2010). In particular, research and innovative solutions for production systems are needed to help firms respond to market evolutions (Fratini et al., 2020). Research on design and development processes is thus needed to meet current challenges (Wynn et al., 2019).
The ability to design changes is essential for the survival and prosperity of manufacturing firms (ElMaraghy and Wiendahl, 2009). Equally important is the ability to design systems that can adapt to changes. To accommodate shortened product and process life cycles (Wiendahl et al., 2007), assembly systems should be designed for change (Hu et al., 2011) and frequent product variation (Heilala and Voho, 2001). That is to say, factories and manufacturing technologies should be capable of producing both current and future product generations (ElMaraghy and Wiendahl, 2009). According to Ross et al. (2008), designing changeable systems with such capabilities increases the value delivered over a system’s lifecycle. Changeability is an umbrella concept encompassing multiple paradigms relating to the ability to handle variation, one of which is flexibility (ElMaraghy and Wiendahl, 2009). Flexibility refers to the ability to cope with changes in different dimensions without incurring significant transition penalties or adversely affecting performance outcomes (Koste and Malhotra, 1999).Because of the importance of flexibility, the capacity for change should be considered during the process of assembly system design. However, designing flexible systems remains challenging.
1.2 Problem description
No single design process will be suitable for all design problems, and the complexity of design processes prevents their comprehensive description using a single model (Wynn and Clarkson, 2018). Therefore, design processes, despite showing common patterns, should be structured to deliver an expected product (Gedenryd, 1998); in the context of this research, the expected product is a flexible assembly system. The following section elaborates the research problem by examining the nature of design processes and flexible assembly systems, before outlining the challenges arising from the relationship between design processes and assembly system flexibility.
1.2.1 Design processes
Engineering design processes are means to generate design solutions that can be implemented successfully. In industrial firms, design processes are conducted within the context of projects (Karlsson et al., 2009). To conduct a project within a firm, those involved must secure a budget and the necessary resources, and complete their work within a set deadline. Engineering design projects have additional specific requirements. Managers of design engineering projects must effectively oversee and guide the work of the design team and its output, as well as the factors influencing the design team (Hales and Gooch, 2004). Design processes are fundamental to engineering design projects. These processes can be divided into distinct phases, each associated with specific activities/tasks, and are sensitive to
factors including organisational structure (people), institutional knowledge, the array of tools and methods available for use, and the context in which they are conducted (Blessing and Chakrabarti, 2009). Consideration of both management and design factors is thus required to adequately support engineering design work (Gericke and Blessing, 2012).
Design processes may or may not be formalized; regardless of their formalisation, they often rely heavily on experience and tacit knowledge. It has been shown that design work can be facilitated by improving working processes, including reviewing the procedures used in firms (Lager et al., 2010). To guide design processes, engineering design projects could use design process models that attempt to describe real design processes in an abstract way (O’Donovan et al., 2005, p.62). The applicability of design process models found in the literature is not always clear (Wynn and Clarkson, 2005). It has been suggested that their use could be increased by interpreting design processes in the context of individual firms, which can be classified by considering factors such as the company’s structure, manufacturing process, suppliers, market/customers, products, and local environment (Maffin et al., 1995). It is important to also recall that design processes in firms are rarely isolated from other plans and processes (Eckert and Clarkson, 2010) but they rarely explicitly address the iteration of other processes and its role in the creation of final products (Gericke and Blessing, 2012). It has been noted that design processes for production systems have received less attention than product design processes (Bellgran and Säfsten, 2010); whereas “product development” is often discussed, the same is not true for “production development” (Vielhaber and Stoffels, 2014). Since design processes are closely related to the systems being designed, deeper specific knowledge of flexible assembly systems is needed.
The nature of design processes must be understood to develop working procedures that structure the design process in a manner appropriate to their purpose. To obtain such an understanding, it will be necessary to identify the elements of design processes, the factors influencing them, and their potential impacts (Wynn and Clarkson, 2005).
1.2.2 The concept of flexible assembly systems
The concept of flexible assembly system has evolved over time. When first proposed in the 1970s, assembly system flexibility was understood to imply extensive automation (Nof et al., 1997), for example through the use of all-purpose machines or robots to perform diverse tasks for multiple products (CIRP, 2014). These highly automated systems were commonly referred to as Flexible Assembly Systems (FAS). This view of assembly system flexibility as something that depends entirely on high automation is incomplete. Since at least 1994, scholars have evaluated the flexibility of assembly systems based partly on their level of automation but also on the basis of parameters such as volume, product variety, and batch size (Rampersad, 1994, Heilala and Voho, 2001, Lotter and Wiendahl, 2009, Rosati et al., 2013). From this perspective, manual and semi-automatic assembly
factors including organisational structure (people), institutional knowledge, the array of tools and methods available for use, and the context in which they are conducted (Blessing and Chakrabarti, 2009). Consideration of both management and design factors is thus required to adequately support engineering design work (Gericke and Blessing, 2012).
Design processes may or may not be formalized; regardless of their formalisation, they often rely heavily on experience and tacit knowledge. It has been shown that design work can be facilitated by improving working processes, including reviewing the procedures used in firms (Lager et al., 2010). To guide design processes, engineering design projects could use design process models that attempt to describe real design processes in an abstract way (O’Donovan et al., 2005, p.62). The applicability of design process models found in the literature is not always clear (Wynn and Clarkson, 2005). It has been suggested that their use could be increased by interpreting design processes in the context of individual firms, which can be classified by considering factors such as the company’s structure, manufacturing process, suppliers, market/customers, products, and local environment (Maffin et al., 1995). It is important to also recall that design processes in firms are rarely isolated from other plans and processes (Eckert and Clarkson, 2010) but they rarely explicitly address the iteration of other processes and its role in the creation of final products (Gericke and Blessing, 2012). It has been noted that design processes for production systems have received less attention than product design processes (Bellgran and Säfsten, 2010); whereas “product development” is often discussed, the same is not true for “production development” (Vielhaber and Stoffels, 2014). Since design processes are closely related to the systems being designed, deeper specific knowledge of flexible assembly systems is needed.
The nature of design processes must be understood to develop working procedures that structure the design process in a manner appropriate to their purpose. To obtain such an understanding, it will be necessary to identify the elements of design processes, the factors influencing them, and their potential impacts (Wynn and Clarkson, 2005).
1.2.2 The concept of flexible assembly systems
The concept of flexible assembly system has evolved over time. When first proposed in the 1970s, assembly system flexibility was understood to imply extensive automation (Nof et al., 1997), for example through the use of all-purpose machines or robots to perform diverse tasks for multiple products (CIRP, 2014). These highly automated systems were commonly referred to as Flexible Assembly Systems (FAS). This view of assembly system flexibility as something that depends entirely on high automation is incomplete. Since at least 1994, scholars have evaluated the flexibility of assembly systems based partly on their level of automation but also on the basis of parameters such as volume, product variety, and batch size (Rampersad, 1994, Heilala and Voho, 2001, Lotter and Wiendahl, 2009, Rosati et al., 2013). From this perspective, manual and semi-automatic assembly
has high flexibility and can be more suitable for the production of large numbers of product variants in small individual quantities. Currently, Industry 4.0 and smart factories are expected to increase flexibility (Davies, 2015). These technological advances present new challenges for the design of assembly systems, such as the need to account for Human – Industrial Robot Collaboration (HIRC). Ore (2020) states that HIRC combines human senses with the efficiency of industrial robots. This implies that “a human worker and a robot work simultaneously on the same product”(Bauer et al., 2016, p. 9). Taking the above into account, it becomes apparent that assembly systems can display different levels of flexibility with respect to different parameters, and that flexibility within the framework of industry 4.0 also depends on other parameters such as HIRC, interoperability, and the type of tasks being performed (Fasth Berglund et al., 2020). It is also clear that a system’s flexibility cannot be properly assessed by considering only technological aspects, especially since new production designs typically involve both technological and organisational changes (Reichstein and Salter, 2006).
An assembly system can be defined as a collection of organised and interrelated components that work together to accomplish a logical and purposeful end (Wu, 1992, p. 31). It is well known that diverse products can be created during final assembly by combining parts and modules according to customers’ demands. Assembly systems are shaped by human and technical systems and also by information systems, management and goal systems, and the products to be manufactured (Hubka and Eder, 1984), as well as the material handling system (Finnsgård et al., 2011) and physical facilities (Bennett and Forrester, 1993), including the layout of the assembly system, the configuration, and the flows through the system (Berggren, 1992). Curiously, the flexibility literature discusses several dimensions relating to the assembly system as a whole (Koste and Malhotra, 1999), but these are rarely included in definitions of flexible assembly systems. The need for a holistic view when designing assembly systems has been highlighted, however (Bellgran, 1998). This indicates a need to understand how flexibility is achieved in assembly systems and to identify the way flexibility dimensions are considered during their design.
1.2.3 The relationships between design processes and flexible assembly systems
The relationship between the characteristics of design processes and complex designs is not well understood (Eckert et al., 2017). There is no consensus regarding optimal design processes for flexible assembly systems. According to Kampker et al. (2019), despite various theoretical and industrial contributions, there is a current need of design approaches for flexible assembly systems. Designs must take flexibility into account (Saleh et al., 2009, Brettel et al., 2016). However, this is considered difficult to achieve; Kouvelis et al. (2005) note that there is little clarity on how to design or build the desired levels of flexibility into a system. Accordingly, Terkaj et al. (2009b) argue that a deeper understanding of design in the relation to the need of flexibility is required. Assembly systems are complex, with many interacting components (Simon, 1996, p. 184), and the greater the number of
has high flexibility and can be more suitable for the production of large numbers of product variants in small individual quantities. Currently, Industry 4.0 and smart factories are expected to increase flexibility (Davies, 2015). These technological advances present new challenges for the design of assembly systems, such as the need to account for Human – Industrial Robot Collaboration (HIRC). Ore (2020) states that HIRC combines human senses with the efficiency of industrial robots. This implies that “a human worker and a robot work simultaneously on the same product”(Bauer et al., 2016, p. 9). Taking the above into account, it becomes apparent that assembly systems can display different levels of flexibility with respect to different parameters, and that flexibility within the framework of industry 4.0 also depends on other parameters such as HIRC, interoperability, and the type of tasks being performed (Fasth Berglund et al., 2020). It is also clear that a system’s flexibility cannot be properly assessed by considering only technological aspects, especially since new production designs typically involve both technological and organisational changes (Reichstein and Salter, 2006).
An assembly system can be defined as a collection of organised and interrelated components that work together to accomplish a logical and purposeful end (Wu, 1992, p. 31). It is well known that diverse products can be created during final assembly by combining parts and modules according to customers’ demands. Assembly systems are shaped by human and technical systems and also by information systems, management and goal systems, and the products to be manufactured (Hubka and Eder, 1984), as well as the material handling system (Finnsgård et al., 2011) and physical facilities (Bennett and Forrester, 1993), including the layout of the assembly system, the configuration, and the flows through the system (Berggren, 1992). Curiously, the flexibility literature discusses several dimensions relating to the assembly system as a whole (Koste and Malhotra, 1999), but these are rarely included in definitions of flexible assembly systems. The need for a holistic view when designing assembly systems has been highlighted, however (Bellgran, 1998). This indicates a need to understand how flexibility is achieved in assembly systems and to identify the way flexibility dimensions are considered during their design.
1.2.3 The relationships between design processes and flexible assembly systems
The relationship between the characteristics of design processes and complex designs is not well understood (Eckert et al., 2017). There is no consensus regarding optimal design processes for flexible assembly systems. According to Kampker et al. (2019), despite various theoretical and industrial contributions, there is a current need of design approaches for flexible assembly systems. Designs must take flexibility into account (Saleh et al., 2009, Brettel et al., 2016). However, this is considered difficult to achieve; Kouvelis et al. (2005) note that there is little clarity on how to design or build the desired levels of flexibility into a system. Accordingly, Terkaj et al. (2009b) argue that a deeper understanding of design in the relation to the need of flexibility is required. Assembly systems are complex, with many interacting components (Simon, 1996, p. 184), and the greater the number of
connections between components, the more likely it is that changes in one part will propagate to another (Eckert et al., 2004). It has been suggested that for a system to be able to change, all of its elements must be designed with characteristics that enable change (ElMaraghy, 2009a, Azab et al., 2013). The analysis of assembly systems and their flexibility can be facilitated by describing them comprehensively including their functions and behaviour (i.e. the way they transform inputs into outputs), their structure (their components and the relationships between them), and their position within hierarchies (the larger systems of which the system under study is itself a component) (Seliger et al., 1987).
It has been also noted that firms may have multiple core plans and stakeholders in need to referring to several plans, giving rise to cross-domain interactions. This necessitates the use of integrative representations to support engineering design practice (Eckert et al., 2017). Additionally, it indicates that better understanding these cross-domain links is required when considering design processes for flexible assembly systems.
Product and volume flexibility are key flexibility dimensions for modern assembly systems (Heilala and Voho, 2001) because of the increasing need to assemble diverse products using a single system and to rapidly assemble specific products desired by a customer so as to bring them quickly to market. These requirements are key drivers of efforts to increase design flexibility. Relationships between different flexibilities in manufacturing contexts have been examined (Browne et al., 1984), and should be explored further in relation to assembly. Flexibility of products has also been studied (Bischof and Blessing, 2008), but little is known in relation to design processes for flexible assembly systems.
In addition to qualitative aspects of design processes such as planning, activities, and challenges, studies have highlighted the need to express firms’ flexibility requirements from a production perspective, in operational and pragmatic terms (Terkaj et al., 2009a). Defining flexibility requirements clearly and quantitatively can help guide and inform decision-making processes (Chryssolouris, 2006). Therefore, both quantitative and qualitative data of flexibility are needed. Finally, it should be noted that the literature offers little empirical data on design working procedures, i.e. what is considered, when and “how” design processes for flexible assembly systems are actually performed.
Overall, the relationship between the design process and flexible assembly systems is still not well understood. The identification of factors influencing the relationship between design processes and assembly system flexibility could enable the development of improved design working procedures to better support the creation of flexible assembly system solutions.
Based on the above problem description, a research objective and research questions were formulated. These are specified in the following section.
connections between components, the more likely it is that changes in one part will propagate to another (Eckert et al., 2004). It has been suggested that for a system to be able to change, all of its elements must be designed with characteristics that enable change (ElMaraghy, 2009a, Azab et al., 2013). The analysis of assembly systems and their flexibility can be facilitated by describing them comprehensively including their functions and behaviour (i.e. the way they transform inputs into outputs), their structure (their components and the relationships between them), and their position within hierarchies (the larger systems of which the system under study is itself a component) (Seliger et al., 1987).
It has been also noted that firms may have multiple core plans and stakeholders in need to referring to several plans, giving rise to cross-domain interactions. This necessitates the use of integrative representations to support engineering design practice (Eckert et al., 2017). Additionally, it indicates that better understanding these cross-domain links is required when considering design processes for flexible assembly systems.
Product and volume flexibility are key flexibility dimensions for modern assembly systems (Heilala and Voho, 2001) because of the increasing need to assemble diverse products using a single system and to rapidly assemble specific products desired by a customer so as to bring them quickly to market. These requirements are key drivers of efforts to increase design flexibility. Relationships between different flexibilities in manufacturing contexts have been examined (Browne et al., 1984), and should be explored further in relation to assembly. Flexibility of products has also been studied (Bischof and Blessing, 2008), but little is known in relation to design processes for flexible assembly systems.
In addition to qualitative aspects of design processes such as planning, activities, and challenges, studies have highlighted the need to express firms’ flexibility requirements from a production perspective, in operational and pragmatic terms (Terkaj et al., 2009a). Defining flexibility requirements clearly and quantitatively can help guide and inform decision-making processes (Chryssolouris, 2006). Therefore, both quantitative and qualitative data of flexibility are needed. Finally, it should be noted that the literature offers little empirical data on design working procedures, i.e. what is considered, when and “how” design processes for flexible assembly systems are actually performed.
Overall, the relationship between the design process and flexible assembly systems is still not well understood. The identification of factors influencing the relationship between design processes and assembly system flexibility could enable the development of improved design working procedures to better support the creation of flexible assembly system solutions.
Based on the above problem description, a research objective and research questions were formulated. These are specified in the following section.
1.3 Objective and research questions
The purpose of the research is to increase knowledge on how to achieve flexible assembly systems through design processes.
The objective of this research is to contribute to the development of working procedures to support design processes of flexible assembly systems.
The following research questions (RQ) have been formulated:
RQ1 What factors are involved in the design process of flexible assembly systems? RQ2 How do the identified factors influence the design process to achieve flexible
assembly systems?
1.4 Scope and delimitations
Figure 1 shows the different phases in the development of an assembly system according to Bellgran (1998). The phases constituting the design process are highlighted, and do not include system realisation and start-up. Multiple design processes were studied in this work, all of which were implemented in the form of projects conducted within firms.
Figure 1. Assembly system development phases and delimitation of the research. The design processes and assembly systems studied in this work involved semiautomatic assembly lines for a range of different products and variants or introduction of new products. In addition, assembly lines are currently the most common type of assembly system in Sweden (Blomquist et al., 2013).
When conducting the research presented in this thesis, the author was an industrial PhD student within the Innofacture Research School and had access to a global automotive company manufacturing heavy-duty vehicles. Consequently, this work has focused primarily on the automotive industry, and the production of heavy-duty vehicles in particular. The participation of an additional company was facilitated via the Innofacture Research School.
Specific choices made, positions adopted, and delimitations imposed during this work are presented in section 2 (theoretical framework). This work focused on
Engineering Design Project
Engineering Design Process
Early phases in the development of assembly systems Management
and Control Preparatory Design SpecificationDesign Realisation Start-up
1.3 Objective and research questions
The purpose of the research is to increase knowledge on how to achieve flexible assembly systems through design processes.
The objective of this research is to contribute to the development of working procedures to support design processes of flexible assembly systems.
The following research questions (RQ) have been formulated:
RQ1 What factors are involved in the design process of flexible assembly systems? RQ2 How do the identified factors influence the design process to achieve flexible
assembly systems?
1.4 Scope and delimitations
Figure 1 shows the different phases in the development of an assembly system according to Bellgran (1998). The phases constituting the design process are highlighted, and do not include system realisation and start-up. Multiple design processes were studied in this work, all of which were implemented in the form of projects conducted within firms.
Figure 1. Assembly system development phases and delimitation of the research. The design processes and assembly systems studied in this work involved semiautomatic assembly lines for a range of different products and variants or introduction of new products. In addition, assembly lines are currently the most common type of assembly system in Sweden (Blomquist et al., 2013).
When conducting the research presented in this thesis, the author was an industrial PhD student within the Innofacture Research School and had access to a global automotive company manufacturing heavy-duty vehicles. Consequently, this work has focused primarily on the automotive industry, and the production of heavy-duty vehicles in particular. The participation of an additional company was facilitated via the Innofacture Research School.
Specific choices made, positions adopted, and delimitations imposed during this work are presented in section 2 (theoretical framework). This work focused on
Engineering Design Project
Engineering Design Process
Early phases in the development of assembly systems Management
