Complexity-oriented ramp-up of assembly systems

Challenges in assembly system ramp-up include singularity of each assembly system, high complexity and resulting instable system behavior, frequently leading to losses. The planning of a dedicatedly staged assembly system ramp-up allows for successful dealing with complexity and thus limits instabilities, as is shown in this paper. It provides a newly-developed assembly system ramp-up approach which addresses key challenges of ramp-up situations and allows for higher migration stability and eventually shorter time-to-volume. Along with the proposed planning methodology, a newly developed ramp-up control method is confirmed by industry experts to contribute to time-to-volume and ramp-up cost reductions. An exemplary case study validates the approach and illustrates practical implications for the manufacturing industry.