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Types and Usage of Assembly Priority Charts in a Modular Assembly System

Conference Paper in DEStech Transactions on Engineering and Technology Research · August 2017
DOI: 10.12783/dtetr/icpr2017/17645

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24th International Conference on Production Research (ICPR 2017)
ISBN: 978-1-60595-507-0

TYPES AND USAGE OF ASSEMBLY PRIORITY CHARTS

IN A MODULAR ASSEMBLY SYSTEM

W. Kern 1, 2, T. Bauernhansl 1, 3
1 GSaME Graduate School of Excellence advanced Manufacturing Engineering, University of Stuttgart, Stuttgart, Germany
2 Audi AG, Ingolstadt, Germany

3 Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Stuttgart, Germany

Abstract
The increasing diversity and dynamics in the automotive market require more flexible and changeable
automotive assembly configurations. However, when dealing with alternative assembly concepts, the methods
for planning and operating an automotive assembly as well as the used information have to be adapted.
A modular assembly system with uncoupled workstations and a flexible flow of products through the system,
e.g. requires an assembly priority chart to plan and control the cyber-physical assembly system.
In this paper, the different types and characteristics of the required assembly priority charts and their usage for
planning and controlling a modular assembly system are described as well as the methods to generate them.
Moreover, the assembly priority charts from a case study of a German automotive subassembly are shown and
discussed. By this, the required level of flexibility and changeability of future automotive assembly systems can
be enabled.

Keywords:
Assembly, automotive assembly, cyber-physical production systems, modular assembly, modularity.

1 INTRODUCTION
The diversity and dynamics in the automotive industry have The precedence constraints of assembly processes, for
been increasing in recent years due to a turbulent global example, are required for assembly line balancing. Such
market environment, shorter lifecycles of products and assembly priority charts (APCs) are needed on a very
technologies as well as the related and ongoing detailed level of single process steps and are thus very
differentiation and individualization of products [1, 2]. This complex. Moreover, for assembly line balancing they are
trend is expected to continue in the future because used in a complex interaction with other constraints
alternative drive concepts, additional types of usage, or regarding logistics, equipment or infrastructure. As a
new materials and technologies emerge [3]. As a consequence, assembly priority charts are in general not
consequence, the level of flexibility and changeability in explicitly documented in the industrial environment but are
automotive manufacturing has to be increased rather known implicitly [4].
correspondingly, especially in automotive assembly However, to enable an individual flow of products in a
systems where the largest part of product variety is created modular, self-controlling assembly system, the assembly
[4, 5]. Two basic enablers to reach this higher flexibility and priority chart of a product is definitely required. By this, an
changeability are modularization on the one side [6, 7, 8], interaction with the other elements of the cyber-physical
and interconnected, self-controlling systems on the other production system can be established to control and
side [9, 10]. By this, the potentials of smart factories and optimize the assembly system and to react to variations,
the anticipated fourth industrial revolution can be utilized disturbances and changes in the system. Hence, to plan
[3, 11]. In this context, flexible and changeable assembly and control a modular cyber-physical assembly system,
configuration concepts with uncoupled, modular current product and production data have to be transferred
workstations and an individual flow of products through the into an assembly priority chart in a structured and efficient
assembly system are being developed [12, 13]. They are way and in the required level of detail. By this, alternative
based on interconnected objects in a cyber-physical assembly configurations can be realized and enable the
production system [3, 10], i.e. products being aware of their required flexibility and changeability in future automotive
required assembly processes, their precedence constraints assembly systems can be enabled.
and their current status of assembly as well as
workstations being aware of their capabilities, their current The paper is organized as follows. In Section 2, the
workload and their upcoming production program [12, 13]. situation in current automotive assembly systems,
especially mixed-model assembly lines, is described as
However, such modular assembly configurations also well as the basics of graph theory to document and
require an adapted production planning and controlling in visualize an assembly priority chart. The characteristics of
contrast to current automotive assembly systems [10, 14]. a modular automotive assembly system are outlined in
Today, nearly all existing large-scale automotive assembly Section 3, and its requirements towards an assembly
systems follow assembly line production principles. In this priority chart are described as well in this section.
context, assembly line balancing is applied to assign In Section 4, the two methods to gain and record this
assembly tasks to workstations along an assembly line, required information are explained and the two required
and customer orders are sequenced to avoid excessive types of assembly priority charts as well as their usage in a
workload variations at the single workstations [15, 16]. As modular cyber-physical assembly system are described.
the flow of products is predefined by the conveyor belt and These two types of assembly priority charts from a case
thus one identical order of assembly is implemented for all study of a German automotive subassembly are shown
products in an assembly line production, the requirements and discussed in Section 5. Following this, Section 6
towards product data and production data for planning, summarizes and concludes the paper.
scheduling and operating an assembly system are
different.

411
2 BACKGROUND
2.1 Assembly line production in the automotive
industry
Assembly line production is the dominant assembly system
configuration in large-scale automotive assembly. It is
characterized by the synchronized movement of products
along an assembly line while they are sequentially
assembled [5, 15].
The method to assign assembly tasks to workstations
along an assembly line and to define one sequential order
of assembly is called assembly line balancing [15].
Therefore, the smallest possible assembly process steps
are defined and balanced on the workstations of an
assembly line production. By this, a high and balanced
utilization of all workers along the assembly line should be
reached. For this assignment, not only the cycle time or
worker utilization, but also accessibility, ergonomics,
material supply areas, working height, required equipment Figure 1. Liaison graph of eight components (schematic).
and predecessor-successor-relations of the respective
assembly processes have to be considered [4, 15]. In this context, a precedence graph or assembly priority
Moreover, usually two subsequent product generations chart is the graph-theoretical description of such an
have to be assembled in one assembly line production in assembly process. The nodes of the graph are the
parallel for a certain period of time, limiting the changes assembly processes and the edges between the nodes
and improvements regarding product concepts in general describe the technical constraints of these processes for a
and precedence constraints in particular. product to be assembled [15]. Assembly priority charts are
directed graphs – visualized by having arrows as edges –
2.2 Mixed-model lines and product mix variations as these edges represent a technical order of assembly,
However, in current automotive assembly systems, not i.e. a direct predecessor-successor-relation between two
only two product generations have to be assembled for a assembly processes [15]. As one assembly process cannot
certain period of time in parallel, but mixed-model be a (direct or indirect) predecessor and successor of
assembly lines are established with several models, each another assembly process at the same time, such graphs
having numerous variants and features and thus a variant- are non-cyclic ones and have at least one initial node to
dependent assembly time at the single workstations of the start the assembly process [15], see Fig. 2.
assembly line production [15]. Moreover, a weight is assigned to the nodes of the graph in
For this reason, assembly line balancing becomes very terms of the predefined assembly time for the respective
complex and has to be accomplished by the sequencing of assembly process [15]. By having the precedence graph or
the product mix of a production program to an assembly assembly priority chart of a product to be assembled,
line in a suitable sequence in order to level workloads all feasible assembly sequences can be deduced from the
along the assembly line [16]. However, based on customer graph [4].
orders, this product mix is also volatile over time.
In addition to that, several other efforts have to be made to
either decrease or control the effects of assembly time
variety caused by the different models, product variants
and features of the production program in a mixed-model
assembly line [17]. Design for manufacturing and
assembly, the building of subassemblies or specific
workstation designs are exemplary measures to decrease
assembly time variety. Worker drifting, feature-specific
workplaces or additional supporting workers, for example,
help to handle the varying assembly times and changing
product mix in a mixed-model assembly line [17].
Figure 2. Assembly priority chart (schematic).
2.3 Assembly priority charts based on graph theory
The assembly tasks to be performed in such an automotive Depending on the level of detail of the described assembly
assembly system are defined by the components of the processes, assembly priority charts can be very complex
resulting product and the assembly processes to assemble [4]. However, due to the low abstraction level which is
these components [15]. Graph theory is often used for the needed for assembly line balancing, assembly priority
description and visualization of such product structures and charts are generally not documented in automotive industry
production processes [4, 15]. Within product development, on the level of assembly steps [4]. Therefore, the
for example, a liaison graph describes the components of a knowledge about predecessor-successor-relations is often
product (as nodes) and their physical connections (as implicit and not transparent.
edges) [4], see Fig. 1.
Moreover, when having more than one product in a
Based on product data like the liaison graph, production production system – as in mixed-model assembly lines –
planning is transforming these physical relations between different assembly priority charts have to be merged to a
components into production processes. To establish a mixed graph [15]. Here, average assembly times are used
process and to generate an assembly sequence, one main according to the production rates of an assembly task in a
component on a workpiece carrier or even an empty certain product mix in an existing or estimated production
workpiece carrier is the initial starting point for the program.
subsequent assembly processes [4], e.g. a body-in-white
on a skid in an automotive assembly system.

412
 balancing of an assembly line production system [4, 12],
3 A MODULAR AUTOMOTIVE ASSEMBLY SYSTEM see Section 2.3.
AND ITS REQUIREMENTS TOWARDS AN APC Moreover, as the variable order of assembly allows
In a cyber-physical production system – like the modular different product flows for different product variants, there
assembly system developed by the authors – all main is no need for building one standardized order of assembly
objects like products, workstations or workers are for all product variants in a modular assembly system [12].
represented by virtual entities. Hence, their status is As a consequence, varying predecessor-successor-
transparent and they are interconnected to the other relations of different product variants, which cause
objects of the cyber-physical production system. By this, additional efforts in an assembly line production, can be
their interaction to schedule, control and optimize the easily handled by the flexible flow of products in the
processes in the assembly system is enabled in order to modular automotive assembly system.
reach a high utilization of resources as well as a flexible For each assembly task of the respective products to be
reaction to variations, disturbances and changes. assembled in the system, the following information is
required:
3.1 Characteristics of the modular assembly system
● direct predecessor task(s)
The three main characteristics of this modular automotive
assembly system are [12]: ● production rate of each (variant of an) assembly task
● uncoupled workstations without a defined cycle time, ● assembly time of each (variant of an) assembly task
● flexible product flows by automated guided vehicles,
● integrated production logistics processes [18]. With having this information an assembly priority chart can
be documented, visualized and used according to the
descriptions in Section 4.2 and Section 4.3.
According to these main characteristics, this alternative to
assembly line production in the automotive industry has a
variable order of assembly instead of a sequential and 4 TYPES AND USAGE OF ASSEMBLY PRIORITY
standardized one along an assembly line [12]. The variable CHARTS IN A MODULAR ASSEMBLY SYSTEM
order of assembly is only determined by the technical In this section, the two different types of assembly priority
constraints recorded in a product variant’s assembly charts and their usage in a modular, cyber-physical
priority chart, see Section 2.3. The possible workstations in assembly system are described. Prior to this, the two
a specific situation are defined by these constraints. The sources to generate this required data are outlined.
assignment to one subsequent workstation is dependent
on the current status of the product, the current workload of 4.1 Generation of APCs from existing data
the possible workstations as well as on the current distance In general, there are two possible sources to generate the
between them [12]. Hence, the operation and control of the required assembly priority chart on the level of assembly
modular assembly system is based on a decentralized tasks from existing production data or product data:
decision-making and interconnected objects in the cyber- ● aggregation from assembly process data
physical production system. By this, a self-controlled and
● derivation from product-structure data
self-optimized flow of products can be reached which is
reacting to the individual situation inside the assembly
system [9, 10]. Aggregation from assembly process data
With this new approach to configure a large-scale, highly In case of an already established production process – e.g.
flexible and changeable mixed-model assembly system, of an existing assembly line – the single assembly steps,
the methods to plan and control an assembly system are their predefined process times and production rates can be
different to assembly line production configurations [12, used for the generation of the required assembly priority
14]. In an assembly system with uncoupled workstations chart on the level of assembly tasks.
both the assignment of assembly processes to Therefore, a two-step approach is applied:
workstations as well as the controlling of the flexible flow of
products and materials is changed. As a result, the 1. Group assembly steps to assembly tasks.
assembly priority chart describing all feasible orders of 2. Define predecessor-successor-relations of assembly
assembly in an explicit and comprehensible way becomes tasks.
a key information for the planning and the (self-)controlling
of such a cyber-physical production system [4, 10]. By this,
the assembly system’s degree of freedom in planning and In this approach, the grouping of assembly steps to
controlling is increased and enables the system’s potential assembly tasks is mainly based on the product structure
regarding the level of flexibility and changeability in and thus the individual components of the product.
comparison to assembly line production [12]. In the Subsequently, the definition of predecessor-successor-
following, the specific requirements towards an assembly relations between the individual assembly tasks is
priority chart for a modular assembly system are outlined. practicable due to the more abstract level of detail, see
Section 2.3.
3.2 Requirements towards an assembly priority chart
The assignment of assembly processes to the uncoupled Derivation from product-structure data
workstations in a modular automotive assembly system is
In case of a new product without existing production
performed on the level of assembly tasks, e.g. the
process data, the required assembly priority charts on the
assembly process of a whole component, as there is no
level of assembly tasks has to be derived from product-
defined and common cycle time for all workstations in the
structure data, e.g. the bill-of-material, liaison graphs or
assembly system [12, 14].
other construction data.
Hence, the required level of detail regarding an assembly
Therefore, an iterative, two-step approach is applied:
priority chart in a modular automotive assembly system is
on the level of assembly tasks as well. Thus, it is more 1. Define predecessor-successor-relations of product
abstract than the very detailed level of every differentiable components.
assembly step as it would be required for the assembly line 2. Transform construction data to process data.

413
 Table 1. APC on workstation level
In this case, the definition of predecessor-successor- (as initial list).
relations is performed on existing data of main components
of the product before the physical relations of components Work- Assembly Predecessor Predecessors
are transformed into production processes containing not station time (sec) (total) (stations)
only construction-related assembly times for the joining of A 68 0 -
parts (i.e. engineering hours per vehicle/product), but also
process-related assembly times regarding the preparation B 84 1 A
of processes, the handling of materials and equipment, the C 76 1 A
walking in the workstation or quality checks. Moreover, a D 90 1 C
production rate for different process variants has to be
estimated. E 86 2 B, D

4.2 Usage in planning a modular assembly system

This initial data set for each product variant is then
The assembly priority chart on the level of assembly tasks dynamically updated during the assembly process inside
generated from production or product data is used as input the modular assembly system. By this, the current status of
data for the assignment of assembly tasks to workstations assembly for each product as well as its possible
in a modular assembly system. By doing this, reasonable workstation in a specific situation and thus all further
workstations of a modular assembly system according to possible orders of assembly are recorded and continuously
product-related and process-related principles are defined, updated in a dynamic assembly priority chart, e.g. see
for details see [14]. Table 2. In this dynamic list of the assembly priority chart
After this assignment of assembly tasks to workstations, on the level of workstations, the performed (or not needed)
the APC on task level can be transferred into an assembly workstations are marked with an assembly time of zero
priority chart of the assembly system’s workstations, see (e.g. Workstations A and C), all other workstations having
Fig. 3. no predecessor to be done at this specific situation are
possible (Workstations B and D) and all workstations
having still one or more workstations to be done as
predecessor are not yet possible for assembly (e.g.
Workstation E).

Table 2. APC on workstation level

(as dynamic list).
Work- Assembly Predecessor Predecessors
Figure 3. APC on workstation level (schematic). station time (sec) (to be done) (stations)
A 0 0 -
This type of assembly priority chart is still containing the B 84 0 -
respective information described in Section 3.2, C 0 0 -
aggregated for each workstation of the assembly system:
D 90 0 -
● direct predecessor workstation(s)
E 86 2 B, D
● production rate (percentage of production program
requiring a specific workstation)
● assembly times (per product variant and as sum of In accordance to this, the individual flow of each product
each workstation) through the assembly system is based on both the required
assembly processes and the status of assembly of a
product as well as on the capable assembly processes and
4.3 Usage in controlling a modular assembly system status of workload of each possible workstation in a
specific situation [4]. Therefore, all products and
This assembly priority chart on workstation level is then
workstations of the modular assembly system have to be
used for production control of a modular assembly system
interconnected and represented by virtual representatives
to realize the flexible flow of production through the system,
in the production control system. As a consequence, the
as it contains all technical constrains regarding the order of
modular assembly concept is based on a cyber-physical
assembly of the products [12], see Fig. 3. Therefore, each
production system. Following this, an efficient product flow,
product variant entering the assembly system gets its initial
high utilization of workstations and a flexible reaction of the
data set containing all required workstations and assembly
assembly system to variations and disturbances can be
times to realize a situation-based decision of the next
realized.
workstation to approach, see Table 1.

414
 Table 3. Four types of graphs, their characteristics and usage.
Type Liaison graph APC (step level) APC (task level) APC (station level)
Nodes Product components Process steps Assembly tasks Workstations
Edges Physical contact Precedence relations Precedence relations Precedence relations
(undirected) (directed, non-cyclic) (directed, non-cyclic) (directed, non-cyclic)
Weight - Assembly time Assembly time Assembly time of
of process step of task variants variants in station
Usage Product development Assembly line Production planning Production control
balancing (often of a modular of a modular
implicit knowledge assembly system assembly system
due to complexity) (static usage) (dynamic usage)
5 APPLICATION AND EVALUATION IN A CASE Then, the assembly priority chart on the level of
STUDY OF THE GERMAN AUTOMOTIVE INDUSTRY workstations is used for the (self-)controlling of products
being assembled in the assembly system. These situation-
5.1 Case study of an automotive subassembly specific decisions are established in a model of the
The methods to generate and use the two different types of described subassembly system in a discrete event
assembly priority charts described in Section 4 are applied simulation, i.e. they are based on these technical
to a case study of a subassembly of the German constraints shown in the assembly priority chart. Therefore,
automotive industry. This subassembly is organized as a each product variant gets its respective assembly priority
large-scale mixed-model assembly line production, chart when entering the assembly system, e.g. see Table
differentiated into 242 single assembly steps. 4, which is then dynamically updated during the assembly
process, as described in Section 4.3. Carrying this
5.2 Application and results information, the product flow in the assembly system can
In this approach, the required assembly priority chart on easily be adapted to variations or disturbances in the
the level of assembly tasks was generated from existing cyber-physical production system, e.g. by blocking one
production process data of the current assembly system, branch of the assembly priority chart of a specific product,
see Section 4.1. In doing so, the 242 single assembly or one workstation of the assembly system for a certain
steps are grouped to 29 assembly tasks, see Fig. 4 [14]. time.
For each assembly task, a production rate and an average
assembly time of a given production program is attached, Table 4. APC on workstation level
with six assembly tasks (No. 1, 2, 12, 18 and 26) being (as initial list).
variant-dependent in terms of having a production rate of
less than 100 %. In this context, it is shown that the Work- Assembly Predecessor Predecessors
required assembly priority chart on assembly task level for station time (sec) (to be done) (stations)
the assignment of assembly processes to workstations is A 68 0 -
less complex than the assembly priority chart needed for B 84 0 -
assembly line balancing with 242 nodes.
C 76 1 A
D 90 2 B, C
E 86 1 D
F 70 1 D
G 58 1 F
H 92 1 F
I 82 3 F, G, H
K 74 1 H
Figure 4. Assembly priority chart with 29 L 82 2 I, K
assembly tasks [14].

This assembly priority chart on the level of assembly tasks 5.3 Implications for science and practice
is then transformed into the assembly priority chart on the After explaining the types, characteristics and usage of
level of workstations during the production planning assembly priority charts in a modular assembly system,
process of a modular assembly system [14], see Section some implications for science and practice have to be
4.2. The resulting assembly system has eleven noticed. Despite the explicit description of all feasible
workstations, see Fig. 5 [14], – with two of them being orders of assembly in an assembly priority chart, the
variant-dependent (Workstations A and B). contained information are modifiable in several
perspectives. First, the structure of a product can be
influenced, and thus the possibilities for subassemblies,
modular products or required production processes.
Second, the technical constraints between assembly tasks
can be influenced by changes of production equipment or
the accessibility of the product. And finally, there is no
definite assignment of assembly tasks to workstations, i.e.
depending on the process to assign assembly tasks to
Figure 5. Assembly priority chart with 11 workstations [14]. workstations, different assembly priority charts on the level
of workstations can be derived.
Moreover, in terms of the dynamic usage of an assembly
priority chart on the level of workstations to control the flow

415
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