Online-control of assembly processes in paced production lines

Abstract Production of complex and large-dimensioned goods in small lot sizes is a demanding task. In order to react to varying customer demand and changing product specifications assembly tasks are executed manually by skilled workers that provide an adequate level of flexibility. Although the task of controlling these assembly processes gets more complex, only little support is given to foreman and production planers in this regard. Existing procedures focus on production planning rather than control of processes. Thus, an assembly control procedure is developed that enables the integration of workers in control of paced assembly processes and a situation specific reallocation of personnel. Foreman and production planers are relieved from time consuming tasks of operational assembly control. The paper describes the approach and experimental results of its application.