An application of design space for assembly process reasoning to utilize current assembly plant resources for new product family members

Abstract

A successful and profitable product platform strategy requires both product family architecture and assembly process reasoning. New product family member production cost and time can be significantly reduced by utilizing available assembly resources, which can be achieved through systematic assembly process reasoning. A method to utilize existing assembly plant resources, during the development of new product family members, requires comparing feasible assembly processes with exiting assembly plants. The set of feasible assembly sequences for a product family member is modelled by developing an assembly sequence design space, which is combinatorial in nature, and applying constraints on the space. Models that capture effects of constraints on these spaces, explicitly represent feasible regions, and efficiently enumerate designs within this space are investigated. The feasible space is then searched to determine new product assembly sequence that will require minimum change in the current assembly plant. An automotive front structure family is utilized to demonstrate application of the assembly sequence space to perform assembly reasoning to increase exiting assembly plant resource utilization.