Combining selective assembly and individualized locator adjustments techniques in a smart assembly line

The availability of automated production lines and production data has opened a new opportunity for improving the geometrical quality of assemblies by using a digital twin in the concept of a smart assembly line. In this concept, a digital twin is generated from scanned data of incoming parts for each assembly. The assembly process is then simulated for the digital twin using variation simulation tools. Subsequently, the optimal production parameters are found by utilizing optimization algorithms along with the simulations so that the geometrical qualities of assemblies are maximum. Two effective production parameters that can be optimized in this concept are the combination of parts and adjustments of locators. The techniques to implement optimize these parameters in the production are referred to as selective assembly and individualized locator adjustments, respectively. This paper evaluates the results of optimizing each parameter separately and both parameters together. To attain this goal, the results of applying the optimal parameters on three industrial cases are determined and compared. The results evidence that the potential of individualized locator adjustment in improving geometrical quality is considerably greater than selective assembly.