Multi-objective Optimization of Automotive Assembly Line Configurations

Marcello Colledani (Politecnico di Milano)

The early-stage design of automotive assembly lines is a critical multi-objective task. The design process is typically carried out in industry by continuous iterations between the process design department and the simulation and systems engineering department.

CHALLENGE - Develop a faster system design procedure to study more potential variable configurations in less time to shorten the time-to-market and generate a re-usable knowledge database to support the early stage design of assembly lines.

SOLUTION - modeFRONTIER evaluated and optimized the performance of the assembly line, as well as the robustness of selected configurations to determine the probability of meeting throughput and cost targets.

BENEFITS - The described methodology was tested at Jaguar Land Rover. The preliminary results reveal doubled production rate, 30% cost and 50% energy reductions, a reduction from 28 to 16 robots and the possibility to merge two door assembly line into a single optimized hybrid line without deteriorating the throughput.