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Flexible manufacturing widely used in the manufacturing industry, but the implementation o a flexible manufacturing system can raise a series of challenges regarding. An area where in the case of flexible manufacturing systems can generate problem and have a significant influence on the production cost is the management of the tool ware. Tool ware can have a significant influence on the cost efficiency of a flexible manufacturing system either trough the high cost of the tool or trough the problems caused the finished pieces during the production process by tools that are not in the specified parameters. The paper will present the main aspects of the tool ware and of the automatic tool rearrangement function, analyze the influence of the ATR in an FMS and present the general aspects of an ART function implementation at the University of Oradea.

The paper takes China Manufacturing 2025 as the background and reviews that intelligent manufacturing talents cultivation is a necessary requirement for increasing capability of independent innovation，promoting China e economic transformation and upgrading and enhancing national competitiveness，hence， the intelligent manufacturing talents cultivation is of great significance. The Engineering and Technical College of fully relies on the provincial experimental teaching demonstration center， namely the engineering construct flexible manufacturing production lines' laboratory for exploring and practicing intelligent manufacturing talents cultivation. And the paper elaborates how to organize and implement engineering training teaching and to acquire the fruitful results in practice teaching， and points that the engineering training teaching is feasible for intelligent manufacturing personnel training. [ABSTRACT FROM AUTHOR]

Means of faster and better technological preparation for multiproduct manufacturing are considered. The possibility of technological preparation in parallel with design and organizational preparation is demonstrated. An approach to organizational and technological design in the development of manufacturing processes is proposed. In this approach, the dynamics and goals of production systems are taken into account. A timeline for the introduction of the proposed approach is outlined, and the conditions for its successful implementation are specified. [ABSTRACT FROM AUTHOR]

This paper addresses cell part scheduling (CPS) problem. In this problem, parts may need to visit machines in different cells with consideration Inter-cell transportation time. The processing route of parts can be flexible. The objective is to minimize the overall process make-span. An integer nonlinear programming (INLP) model is formulated to determine the schedule scheme of all parts. An auction-based heuristic approach is proposed to solve it, which focuses on dealing with cooperation between different cells. In this approach, each cell can act as an auctioneer or a bidder. In an auction, it contains call for auction, bid construction, modify bids and winner announcement. A reference matrix is also applied in the auction to guarantee parts to finish as early as possible. Numerical experiments were conducted to test the auction-based approach. The results demonstrate the effectiveness, sensitivity and stability of the proposed auction-based approach, especially suitable for instances in large scale within a short calculating time. [ABSTRACT FROM AUTHOR]

Large-scale machine coordination is a primary approach for flexible manufacturing, enabling large-scale autonomous machines to dynamically coordinate their actions in pursuit of a custom task. One of the key challenges for such large-scale systems is finding high-dimensional coordination decision-making policies. Multitask policy gradient algorithms can be used in search of high-dimensional policies, particularly in collaborative decision support systems and distributed control systems. However, it is difficult for these algorithms to learn online high-dimensional coordination control policies (CCP) from large-scale custom manufacturing tasks. This paper proposes a large-scale online multitask learning and decision-making approach, which can consecutively learn high-dimensional CCP in order to quickly coordinate machine actions online for large-scale custom manufacturing task. A large-scale online multitask leaning algorithm is developed, which is able to learn large-scale high-dimensional CCP in a flexible manufacturing scenario. An online stochastic planning algorithm is proposed, which online optimizes the Markov network structure in order to avoid expensive global search for the optimal policy. Experiments have been undertaken using a professional flexible manufacturing testbed deployed within a smart factory of Weichai Power in China. Results show the proposed approach to be more efficient when compared with previous works. [ABSTRACT FROM PUBLISHER]

The alignment of optical components is challenging. This paper proposes self-optimisation as a means for reducing planning efforts and increasing the system’s autonomy. Hence, reduced costs and production times can be achieved. Moreover, self-optimising approaches for laser optics assembly enabling autonomous compensation of manufacturing tolerances are presented. Based on ray-tracing simulation, the assembly system carries out the alignment of optics automatically. During the alignment process the laser beam is monitored and analysed. The ray-tracing simulation is updated in a closed-loop manner for gaining information on required correction movements. This information is passed to the assembly system in order to achieve a valid optical function using tolerance-affected components. The choice of metrology as well as the interfaces between different software packages and hardware components will be discussed. The alignment procedure will be described using the example of a miniaturised optical system suitable for laser beam guiding and shaping. [ABSTRACT FROM AUTHOR]

Flexible manufacturing based on rapidly reconfigurable robotic systems will enable factories to meet time-sensitive and fast-changing industrial demands. However, with the rise of modular systems there is also the need to quickly and easily determine which configuration is optimal for performing a certain task. In this article, we present a path-based ad hoc technique for determining the inverse and forward kinematics map based on relative joint space variable to reduce the computational complexity. The proposed technique is nonsingular and suits kinematic analysis and optimization of robotic systems with undetermined configuration, and it can be extended to solve generalized inverse kinematic of robotics system involving large number of joint variable. [ABSTRACT FROM AUTHOR]

This article introduces the concept of a measurement-aided welding cell (MAWC). It then focuses on developing the MAWC for body and chassis components in the automotive industry. Industry 4.0 requires flexibility and reconfigurability from manufacturing systems, which has been addressed by cellular manufacturing systems (CMS). Traditional automotive welding technology is not flexible enough to be used as a CMS. So, the core of automotive production does not meet the needs of next-generation manufacturing and Industry 4.0. For the first time, this demand has been answered-by the MAWC. The MAWC is based on two handling robots, a welding robot and an optical measurement system, all integrated into one welding cell. The measurement system controls guides and gives feedback to the handling and welding robots. This way, accurate welding is based on actual part-to-part adjustment, rather than hard mechanical tooling. The lack of hard mechanical tooling allows flexibility. Measurement-assisted assembly and machining is not new. However, it has not previously been applied to complex welding processes, because traditional measurement technologies have not been satisfactory. A newly developed system using multi-camera measurement technology meets the flexibility requirements. The technology required for a MAWC is reviewed and found to be in common use in the automotive industry. Three development projects are presented in which the main functions of a MAWC are successfully demonstrated. Two of these projects were done with BMW. A MAWC allows the manufacturing process to immediately swap to a different product on the same line, increasing the production line utilisation rate and making it possible to produce several low-volume products in one manufacturing system. So, the MAWC will not only yield benefits from its scalable capacity and global decentralization, but it will also open new business opportunities for manufacturing low-volume luxury car parts or post-production spare parts. [ABSTRACT FROM AUTHOR]

Purpose – The following paper is a “Q & A interview” conducted by Joanne Pransky of Industrial Robot Journal as a method to impart the combined technological, business and personal experience of a prominent, robotic industry engineer-turned successful business leader, regarding the commercialization and challenges of bringing technological inventions to market while overseeing a company. This paper aims to discuss these issues. Design/methodology/approach – The interviewee is Aldo Zini, President and CEO of Aethon, Inc., a robotics and software company that has developed an innovative automated platform to improve internal supply logistics. In this interview, Zini shares some of the technical and business details that have led up to the latest version of Aethon’s core product, the TUG, a mobile autonomous robot with more than 450 installs worldwide. Findings – Zini received a BS in Industrial Engineering from the University of Pittsburgh and a master’s in Public Management (Health Systems IT) from Carnegie Mellon University. While obtaining his BS degree, Zini did an internship in hospital consulting and became immediately interested in healthcare automation as a way to solve hospital inefficiencies. Zini went on to become the Vice President of Sales and Marketing for Automated Healthcare, which developed the first robotic medication dispensing system for hospitals (ROBOT-Rx) and was acquired by McKesson for $67 million. Before joining and investing in Aethon, Zini was Senior Vice President of sales and marketing for TechRx, one of the largest providers of software solutions to the pharmacy industry, which was sold to NDC Corporation for over $200 million. Originality/value – Zini has been leading the technology revolution in hospital automation for more than 25 years. His contributions to technology-driven companies have led to acquisitions worth more than a quarter of a billion dollars. Zini owns several patents in medication-dispensing technology, and is credited with the development of key methodologies in quantifying the value proposition for several technology platforms deployed in hundreds of hospitals across the country. [ABSTRACT FROM AUTHOR]

This work was aimed for developing computational intelligence for scheduling a manufacturing cell's tasks, based manily on genetic algorithms. The manufacturing cell was modelled as beign a production-line; the makespan was calculated by using heuristics adapted from several libraries for genetic algorithms computed in C++ builder. Several problems dealing with small, medium and large list of jobs and machinery were resolved. The results were compared with other heuristics. The approach developed here would seem to be promising for future research concerning scheduling manufacturing cell tasks involving mixed batches.

To address the multi-flexible integrated scheduling problem with setup times, a multi-flexible integrated scheduling algorithm is put forward. First, the operation optimization allocation strategy, based on the principle of the relatively long subsequent path, is proposed to assign the operations to idle machines. Second, the parallel optimization strategy is proposed to adjust the scheduling of the planned operations and machines to make the processing as parallel as possible and reduce the no-load machines. Then, the flexible operation determination strategy is combined with the above two strategies to determine the dynamic selection of the flexible operations as the planned operations. Finally, a potential operation preemptive strategy is proposed to judge whether the planned operations will be interrupted by other operations during their processing. The results show that the proposed algorithm can effectively solve the multi-flexible integrated scheduling with setup times, and it can also better solve the flexible integrated scheduling problem.

Manual forming of sheet metal parts through traditional panel beating is a highly skilled profession used in many industries, particularly for sample manufacturing or repair and maintenance. However, this skill is becoming gradually isolated mainly due to the high cost and lack of expertise. Nonetheless, a cost-effective and flexible approach to forming sheet metal parts could significantly assist various industries by providing a method for fast prototyping sheet metal parts. The development of a new fixtureless sheet metal forming approach is discussed in this article. The proposed approach, named Mechatroforming, consists of integrated mechanisms to manipulate sheet metal parts by a robotic arm under a controlled hammering tool. The method includes mechatronics-based monitoring and control systems for (near) real-time prediction and control of incremental deformations of parts. This article includes description of the proposed approach, the theoretical and modelling backgrounds used to predict the forming, skills learned from manual operations, and proposed automation system being built. [ABSTRACT FROM AUTHOR]

The present paper presents a systematic investigation of both catalyst free and catalyst assisted AlN nanowire synthesis by chemical vapour deposition using Al and NH3 as source materials. Growth runs have mostly been carried out at 1100°C under H2 as carrier gas. While the catalyst free growth runs resulted in long (∼40 μm) and dense AlN nanowire array films, the catalyst assisted growth resulted in short nanowires (3–5 μm). Growth mechanisms have been presented. Raman spectroscopy of the catalyst free grown nanowires has revealed very symmetric and strong phonon modes [e.g. strong E2 (high)] indicating very good crystal quality of the grown AlN nanowires. In brief, catalyst free growth eliminates catalyst contamination and produces high quality and density of long nanowires, which is very valuable for scale-up manufacturing opportunities of the AlN nanostructures. [ABSTRACT FROM AUTHOR]

Flexible manufacturing widely used in the manufacturing industry, but the implementation o a flexible manufacturing system can raise a series of challenges regarding. An area where in the case of flexible manufacturing systems can generate problem and have a significant influence on the production cost is the management of the tool ware. Tool ware can have a significant influence on the cost efficiency of a flexible manufacturing system either trough the high cost of the tool or trough the problems caused the finished pieces during the production process by tools that are not in the specified parameters. The paper will present the main aspects of the tool ware and of the automatic tool rearrangement function, analyze the influence of the ATR in an FMS and present the general aspects of an ART function implementation at the University of Oradea [ABSTRACT FROM AUTHOR]

In this article, we present the development of a simple multiagent-based system for the control of a flexible manufacturing system. We followed the stages of a methodology specially conceived for the development of agent-based system, which is an integration of the classical methodology for agent-oriented analysis and design Gaia, and AUML (Agent-Unified Modeling Language). We adopted as study case the CIMUBB Laboratory at the University of Bio-Bio, which has a flexible manufacturing system including three flexible manufacturing cells interconnected by a conveyor belt. In the analysis stage, we identified roles involved, and we design models representing roles and protocols. In the design stage, we applied Gaia agent, services, and acquaintance models from Gaia, and we complemented with AUML as the adopted methodology suggests. With the developed models, we constructed a fully functional system where each agent was built as an independent process tree. Agents communicate by passing messages through the Ethernet network with socket interfaces. Various tests executed in our laboratory scale manufacturing system show the effectiveness of our implementation. Copyright © 2015 John Wiley & Sons, Ltd. [ABSTRACT FROM AUTHOR]

An approach to reconfigurable distributed model predictive control based on reconfigurable controller dissipativity properties is developed. The dissipativity properties of the controllers are updated online to reconfigure themselves for changes in the process network topology, which may be due to changing product specifications, feedstock type or scheduled or unscheduled maintenance; allowing for more flexible and agile manufacturing processes. The use of dissipative systems theory allows for the interaction effects between individual processes to be taken into account in control design to achieve high levels of plant-wide performance. Plant-wide performance and stability bounds are developed based on dissipative systems theory, which in turn are translated into the dissipative trajectory conditions on each local controller. This approach is enabled by the use of dynamic supply rates in quadratic difference form parameterised as linear functions of the process network structure. [ABSTRACT FROM AUTHOR]

Purpose – The purpose of this paper is to present a technique for assessing and comparing the static and dynamic performance of three different models of small six-axis industrial robots using a Renishaw XL80 laser interferometer system, a FARO ION laser tracker and a Renishaw QC20-W telescoping ballbar. Design/methodology/approach – Specific test methods are proposed in this work, and each robot has been measured in a similar area of its working envelope. The laser interferometer measurement instrument is used to assess the static positioning performance along three linear and orthogonal paths. The laser tracker is used to assess the contouring performance at different tool center point (TCP) speeds along a triangular tool path, whereas the telescoping ballbar is used to assess the dynamic positioning performance for circular paths at different TCP speeds and trajectory radii. Findings – It is found that the tested robots behave differently, and that the static accuracy of these non-calibrated robots varies between 0.5 and 2.3 mm. On the other hand, results show that these three robots can provide acceptable corner tracking at low TCP speeds. However, a significant overshoot at the corner is observed at high TCP speed for all the robots tested. It was also found that the smallest increment of Cartesian displacement (Cartesian resolution) that can be taken by the tested robots is approximately 50 μm. Practical implications – The technique used in this paper allows extremely accurate diagnosis of the robot performance, which makes it possible for the robot user to determine whether the robot is in good or bad condition. It can also help the decision-maker to select the most suitable industrial robot to achieve the desired task with minimum cost and specific application ability. Originality/value – This paper proposed a new method based on the performance verification approach for solving the robot selection problem for flexible manufacturing systems. Furthermore, despite their importance, bidirectional repeatability and Cartesian resolution are never specified by the manufacturers of industrial robots nor are they described in the ISO 9283:1998 guide, and they are rarely the object of performance assessments. In this work, specific tests are performed to check and quantify the bidirectional repeatability and the Cartesian resolution of each robot. [ABSTRACT FROM AUTHOR]

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Purpose – The purpose of this paper is to describe the integration of a gesture control system for industrial collaborative robot. Human and robot collaborative systems can be a viable manufacturing solution, but efficient control and communication are required for operations to be carried out effectively and safely. Design/methodology/approach – The integrated system consists of facial recognition, static pose recognition and dynamic hand motion tracking. Each sub-system has been tested in isolation before integration and demonstration of a sample task. Findings – It is demonstrated that the combination of multiple gesture control methods can increase its potential applications for industrial robots. Originality/value – The novelty of the system is the combination of a dual gesture controls method which allows operators to command an industrial robot by posing hand gestures as well as control the robot motion by moving one of their hands in front of the sensor. A facial verification system is integrated to improve the robustness, reliability and security of the control system which also allows assignment of permission levels to different users. [ABSTRACT FROM AUTHOR]

The major challenge of today's manufacturing industry in tackling demands for a wider range of products with short life-cycle times and meeting customisation requirements has drawn considerable attention towards flexibility in manufacturing systems. As a prominent part of a manufacturing system, an assembly system provides a platform for increasing efficiency while delivering various market demands. However, owing to the dearth of a unified and clear definition of the constituents of flexible assembly systems, in both theory and practice, the recognition of flexibility in assembly systems still remains elusive. In order to establish a sound base for discussing the constituents of flexible assembly systems, this research paper explores the literature concerning flexibility in manufacturing and assembly as well as in flexible systems management domains. To reflect an industrial perspective, a multiple case study of five manufacturing plants in the heavy vehicle industry is performed. By identifying six essential constituents of flexibility in assembly systems, the study proposes a clear definition of flexibility in assembly systems which mainly revolves around mix and volume flexibility. To further enhance the findings, the compatibility of a few previously identified types of manufacturing flexibility in the assembly systems of the case plants is investigated and additional dimensions of flexibility in assembly systems are revealed. Finally, the implications for theory and practice as well as suggestions for future research are discussed. [ABSTRACT FROM AUTHOR]

We study the problem of how to design a sparse flexible process structure in a balanced and symmetrical production system to match supply with random demand more effectively. Our goal is to provide a sparsest design to achieve (1 - ∈) - optimality relative to the fully flexible system. In a balanced system with n plants and n products, Chou et al. (2011) proved that there exists a graph expander with O arcs to achieve (1 - ∈)-optimality for every demand realization. Wang and Zhang (2015) showed that the simple k-chain design with O (n / ∈) arcs can achieve (1 - ∈)-optimality in expectation. In this paper, we introduce a new concept called probabilistic graph expanders. We prove that a probabilistic expander with O (nln(1/∈)) arcs guarantees (1 - ∈)-optimality with high probability (w.h.p.), which is a stronger notion of optimality as compared to the expected performance. Easy-to-implement randomized and deterministic constructions of probabilistic expanders are provided. We show our bound is best possible in the sense that any structure should need at least Ω(nln(1/∈)) arcs to achieve (1 - ∈)-optimality in expectation (and hence w.h.p.). We also show that in order to achieve (1 - ∈)-optimality in the worst case, any design would need at least Ω (n/∈) arcs; and in order to achieve (1 - ∈)-optimality in expectation, k-chain needs at least Ω(n/∈) arcs. [ABSTRACT FROM AUTHOR]

This article presents a designed productive case which includes the virtual laboratories of the Universidad Tecnologica Pereira's Industrial Faculty, it means the flexible manufacturing cell and the mobile logistics laboratory; this case was named "PR ATV's production case". It was structured in trying to imitate a real process of production of ATVs with their logistics process. There is described the form in which is designed the adaptations of existing resources within the manufacturing cell with the aim of to execute the process in the laboratory. [ABSTRACT FROM AUTHOR]

The ability to physically enlarge one's own body structures plays an important role in robustness and adaptability of biological systems. It is, however, a significant challenge for robotic systems to autonomously extend their bodies. To address this challenge, this paper presents an approach using hot melt adhesives (HMAs) to assemble and integrate extensions into the robotic body. HMAs are thermoplastics with temperature dependent adhesiveness and bonding strength. We exploit this property of HMAs to connect passive external objects to the robot's own body structures, and investigate the characteristics of the approach. In a set of elementary configurations, we analyze to which extent a robot can self-reconfigure using the proposed method. We found that the extension limit depends on the mechanical properties of the extension, and the reconfiguration algorithm. A five-axis robot manipulator equipped with specialized HMA handling devices is employed to demonstrate these findings in four experiments. It is shown that the robot can construct and integrate extensions into its own body, which allow it to solve tasks that it could not achieve in its initial configuration. [ABSTRACT FROM AUTHOR]

Traditional tool was difficult to achieve digitisation and precision in manufacturing high-speed train panels. Thus, multi-point tooling was proposed as a novel and flexible manufacturing equipment. In this paper, the principle and implementation of multi-point tooling were described, and the key techniques in stretching and trimming process were discussed. To verify the feasibility and manufacturing effects in application, typical high-speed train panels forming process was carried out with multi-point tooling and commercial finite-element software, respectively. Comparison and analysis of strain distribution, thinning rate in thickness and shape errors were made between simulation results and experimental results. The results show consistency and may provide instructive guidance on high-speed train panels manufacturing. [ABSTRACT FROM AUTHOR]

Purpose – The purpose of this paper is to illustrate the importance of redesigning, reusing, remanufacturing, recovering, recycling and reducing (6R) to sustainable manufacturing and discuss the general procedure to reconfigure robots. Two critical challenges in adopting industrial robots in small and medium-sized enterprise (SMEs) are flexibility and cost, as the number of tasks of the same type can be limited because of the size of an SME. The challenges can be alleviated by 6R. The 6R processes allow a robot to adopt new tasks, increase its utilization rate and reduce unit costs of products. Design/methodology/approach – There is no shortcut to implement sustainable manufacturing. All of the manufacturing resources in a system should be planned optimally to reduce waste and maximize the utilization rates of resources. In this paper, modularization and reconfiguration are emphasized to implement 6R processes in sustainable manufacturing; robots are especially taken into consideration as core functional modules in the system. Modular architecture makes it feasible to integrate robots with low-cost customized modules for various tasks for the high utilization rates. A case study is provided to show the feasibility. Findings – Finding the ways to reuse manufacturing resources could bring significant competitiveness to an SME, in the sense that sophisticated machines and tools, such as robots, can be highly utilized even in a manufacturing environment with low or medium product volumes. The concepts of modularization and 6R processes can be synergized to achieve this goal. Research limitations/implications – The authors propose the strategy to enhance the utilization rates of core manufacturing resources using modular architecture and 6R practice. The axiomatic design theory can be applied as the theoretical fundamental to guide the 6R processes; however, a universal solution in the implementation is not available. The solutions have to be tailored to specific SMEs, and the solutions should vary with respect to time. Practical implications – To operate a sustainable manufacturing system, a continuous design effort is required to reconfigure existing resources and enhance their capabilities to fulfill new tasks in the dynamic environment. Social implications – The authors focus on the importance of sustainable manufacturing to modern society, and they achieve this goal by reusing robots as system components in different applications. Originality/value – Sustainable manufacturing has attracted a great deal of attention, although the operable guidance for system implementation is scarce. The presented work has thrown some light in this research area. The 6R concept has been introduced in a modular system to maximize the utilizations of critical manufacturing resources. It is particularly advantageous for SMEs to adopt sophisticated robots cost-effectively. [ABSTRACT FROM AUTHOR]

This document studies the implications of considering or not pending orders (hereinafter called "backorders") in production planning, control and configuration models in flexible manufacturing systems (SMF). In many of the models that attempt to study SMF, the backorder is not considered, and in those in which it is considered, it is included as a passive variable where the impact it may have on said systems and especially its relationship has not been explicitly noted. with the demand pattern. In the present investigation, direct benefits of the inclusion of backorders were identified in capacity utilization, in workload balancing between groups of Machines (cells) and in inventory levels. Finally, it is proposed to use the economic concept of elasticity to measure the real impacts between the backorder and other production factors, a novel strategy in this type of application and which may be the subject of future research.

Purpose - The purpose of this study has been to evaluate the technology of autonomous mobile manipulation in a real world industrial manufacturing environment. The objective has been to obtain experience in the integration with existing equipment and determine key challenges in maturing the technology to a level of readiness suitable for industry. Despite much research within the topic of industrial mobile manipulation, the technology has not yet found its way to the industry. To mature the technology to a level of readiness suitable for industry real-world experience is crucial. This paper reports from such a real-world industrial experiment with two mobile manipulators. Design/methodology/approach - In the experiment, autonomous industrial mobile manipulators are integrated into the actual manufacturing environment of the pump manufacturer Grundfos. The two robots together solve the task of producing rotors; a task constituted by several sub-tasks ranging from logistics to complex assembly. With a total duration of 10 days, the experiment includes workspace adaptation, safety regulations, rapid robot instruction and running production. Findings - With a setup time of less than one day, it was possible to program both robots to perform the production scenario in collaboration. Despite the success, the experiment clearly demonstrated several topics in need of further research before the technology can be made available to the industry: robustness and cycle time, safety investigations and possibly standardization, and robot and workstation re-configurability. Originality/value - Despite the attention of research around the world, the topic of industrial mobile manipulation has only seen a limited number of real-world integrations. This work reports from a comprehensive integration into a real-world running production and thus reports on the key challenges identified from this integration. [ABSTRACT FROM AUTHOR]

Purpose -- The aim of this paper is to develop a detailed descriptive model for kitting operations, allowing resources sizing and computation of systems' economic performances. Design/methodology/approach -- A mathematical model allows to size resources, given product characteristics and production mix, and determines total system costs by assessing relevant cost items including investment costs (vehicles, containers, storage racks), direct operating costs (transport and kitting workforce, vehicles energy consumption and maintenance, quality costs), indirect operating costs (space requirements, work in process (WIP) and safety stock holding costs, administration and control). Findings -- The choice of parts delivery supply to assembly lines requires a thorough economic comparison of alternatives. However, existing models are often simplistic and neglect many critical factors which affect the systems' performances. As a consequence, industries are unsure about which system is best for their environment. This model allows assessment of the cost and suitability of kitting in any specific industrial setting. Results of the model application are case-specific and cannot be generalized, but the major impact of labour and error correction cost has been highlighted. Research limitations/implications -- The model at present focusses on the in-house kitting systems based on travelling kits concept only. Although all quantitative cost drivers are included, some context-related qualitative decision factors are not yet included. The model assumes that the information about product structure and part requirements is known and that a preliminary design of the assembly system (i.e. line balancing) has been carried out. Practical implications -- Production managers are given a quantitative decision tool to properly assess the implementation of kitting policies at an early decision stage. This allows exploring the trade-offs between the alternatives and properly planning the adoption of kitting systems, as well as comparing kitting with alternative material supply methods. Originality/value -- With respect to previous simplified literature models, this new approach allows quantification of a number of additional factors which are critical for successful implementation of cost-effective kitting systems, including kitting errors. An exhaustive cost estimation of kitting systems in multiple, mixed-model assembly lines is thus permitted. Paper type Research paper [ABSTRACT FROM AUTHOR]