Entwicklung einer Methodik für die Planung und Implementierung von flexiblen Montageanlagen in der Automobilproduktion

Abstract

The flexibility of production equipment has become a critical success factor in industrial pro-duction systems. In light of volatile conditions – such as increasing number of product variants, geopolitical uncertainties, and rapid technological advancements – an enhanced responsiveness is imperative to enable the planning and implementation of efficient and future-proof manu-facturing systems. This is particularly relevant in automated automotive assembly, where cur-rent assembly stations are primarily optimized for performance, often at the expense of adapt-ability. Based on a theoretical examination of equipment planning as part of factory planning, this research develops one central research question and three specific sub-questions. Together, these address a theoretical gap in the literature and reflect the practical challenge – limited flexibility of current assembly stations. The overarching research question is: "How can flexi-bility in assembly systems be systematically planned, designed, and conceptually imple-mented?" To answer this question, a multi-stage methodological approach was employed. First, a sys-tematic international literature review on the topics of flexibility, assembly, and automation has been conducted. Based on this analysis, a conceptual flexibility model has been developed. In a subsequent multiple case study involving five international automotive OEMs, the model has been expanded with practical insights to form a practical flexibility model. Data collection has been conducted via expert interviews and participant observations, and the analysis applied a mixed-methods approach and triangulation. Finally, theoretical and practical findings have been synthesized into an integrated model the Assembly Flexibility Model. The resulting model has prototypically been applied in a planning project of a flexible automo-tive assembly station and validated through workshops with industry experts. By systematically integrating factory planning processes, relevant aspects of flexibility, and practical implemen-tation requirements, the developed Assembly Flexibility Model addresses both the identified research gap and practical challenges in industrial assembly planning. Future application of the model is expected to significantly enhance the flexibility of automated assembly systems.