Proactive assessment of basic complexity in manual assembly: development of a tool to predict and control operator-induced quality errors
Journal article, 2017

A major challenge for manufacturing companies today is to manage a huge amount of product variants and build options at the same time in manufacturing engineering and in production. The overall complexity and risk of quality errors in manual assembly will increase placing high demands on the operators who must manage many different tasks in current production. Therefore methods for decreasing and controlling assembly complexity are urgent because managing complex product and installation conditions will result in distinct competitive advantages. The objective of this paper is to present a method for predictive assessment of basic manual assembly complexity and explain how included complexity criteria were arrived at. The verified method includes sixteen high complexity and sixteen low complexity criteria to aid designers in preventing costly errors during assembly and create good basic assembly conditions in early design phases of new manufacturing concepts

design for assembly

complexity analysis

assembly errors

quality control

production planning


basic manual assembly complexity


Ann-Christine Falck

Chalmers, Product and Production Development, Product Development

Roland Örtengren

Chalmers, Product and Production Development, Production Systems

Mikael Rosenqvist

Chalmers, Product and Production Development, Product Development

Rikard Söderberg

Chalmers, Product and Production Development, Product Development

International Journal of Production Research

0020-7543 (ISSN) 1366-588X (eISSN)

Vol. 55 15 4248-4260

Subject Categories

Mechanical Engineering

Production Engineering, Human Work Science and Ergonomics

Driving Forces

Sustainable development

Areas of Advance




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