Empirical comparison of assembly complexity assessment approaches in manufacturing

Investigating assembly complexity is a continuing concern within the manufacturing field, as it may impact the quality and costs of products. A growing body of literature is aimed at developing novel and reliable methods to assess assembly complexity. The first aim of this paper is to provide an extensive literature review, identifying the main approaches to this problem. Three main approaches emerged: product-centred approach, information-centred approach and system-centred approach. A second goal is to conduct a comparative analysis of these approaches, highlighting their advantages and limitations and providing guidance for process and product designers seeking to control assembly complexity. For each approach, a representative method was chosen, analysed in detail, and applied to five different real products. As concluding findings it was observed that product-centred approaches provide a more objective analysis, focusing strictly on product features. On the other hand, information-centred approaches focus on quantity and variety of information handled by assembly operators, thus proposing a valuable link between complexity and effort required. Finally, system-centred approaches provide a holistic assessment of assembly complexity which is typically only qualitative.