Complex assembly variant design in agile manufacturing. Part II: Assembly variant design methodology

In the first paper of this two-part series, the assembly variant design system architecture and complementary assembly methodology were presented. The general complementary assembly models, hierarchical assembly model and relational assembly model, are established which were further specified as the Assembly Variants Model (AVM) and the Assembly Mating Graphs (AMGs) respectively to cater for the needs for assembly variant design. This paper discusses the assembly variant design methodology which is based on these assembly models. The matching components are searched and retrieved from the AVM and then the constraint groups are identified by manipulating the AMGs. Then the assembly variant design process is formulated as a mixed-integer (linear or non-linear) programming problem which is solved using a standard solver or heuristic. This methodology provides a systematic approach to facilitate the variant design of complex assembly products in the agile manufacturing environment. Finally, a prototype system is developed and examples are presented.