Simulation-based potential analysis of line-less assembly systems in the
Increasing product variety, shorter product life cycles, and the ongoing
transition towards electro-mobility demand higher flexibility in
automotive pro-duction. Especially in the final assembly, where most
variant-dependent pro-cesses are happening, the currently predominant
concept of flowing line assem-bly is already been pushed to its
flexibility limits. Line-less assembly systems break up the rigid line
structures by enabling higher routing and operational flex-ibility using
individual product routes that are takt-time independent. Hybrid
ap-proaches consider the combination of line and matrix-structured
systems to in-crease flexibility while maintaining existing
Such system changes require a high planning effort and investment costs.
For a risk-minimized potential evaluation, discrete-event simulation is
a promising tool. However, the challenge is to model the existing line
assembly concept and line-less assembly for comparison.
In this work, a comprehensive scenario analysis based on real assembly
sys-tem data is conducted to evaluate the potential of line-less
assembly in the auto-motive industry. Within the simulation, an online
scheduling algorithm for adap-tive routing and sequencing is used. Based
on an automated experiment design, several system parameters are varied
full-factorially and applied to different sys-tem configurations.
Various scenarios considering worker capabilities, station failures,
material availability, and product variants are simulated in a
discrete-event simulation considering realistic assumptions. Results
show that the throughput and utilization can be increased in the hybrid
and line-less systems when assuming that the stations will have failures
and the assumption of an un-changed order input.