Effects of product design on assembly lines performances : A concurrent engineering approach

Purpose – The paper's aim is to assess the impact of product related features on the performances of assembly line manufacturing systems, also providing a specific Design for Manufacturing and Assembly rating index to assess the goodness of a product design solution with respect to assembly line performances. Design/methodology/approach – A computer simulation‐based parametric analysis was carried out to assess the impact of four major product‐related parameters. 216 different assembly line balance problem instances were evaluated. Findings allowed to develop a DFMA rating index specific for assembly line manufacturing as well as design guidelines. Findings – Assembly sequence degrees of freedom and the ratio of the average task duration to the maximum duration are the most influencing parameters. While the former should be maximized, only a moderate task duration variability was found beneficial. The influence of other factors resulted less marked and changing on a case‐specific basis. Research limitations/implications – Complex interactions between product design features and line performances prevent generalization. The performed numerical experimentation, although extensive, remains somewhat limited respect all possible practical situations. The proposed rating index should be utilized while maintaining an overall perspective about the mutual influence of all parameters. Some suggested guidelines imply a trade off with traditional DFMA guidelines. Practical implications – Product designers are given useful insights, tools and guidelines to develop better producible products. With the proposed ranking index a designer can easily rate his choices when selecting assembly tasks and sequences, as well as rank alternative product designs solutions. Originality/value – The paper presents an original discussion about the impact of product design choices on assembly line performances. The developed DFMA rating index and guidelines are new.