Optimization of wire harness assembly using human–robot-collaboration

Abstract

Wire harness assembly has been predominantly carried out manually so far since full automation has proved to be difficult for the manufacturing of flexible material with many variants. For productivity reasons, human–robot-collaboration (HRC) facilitates new optimization potential for manual systems by encompassing direct joint work of a human operator and a robot, combining their respective strengths at best. To identify HRC potential in wire harness assembly, we follow a cost-effective, simplistic, and easily adaptable approach by introducing an assessment system for analyzing the assembly process with respect to the capability-oriented task allocation between operator and robot. In doing so, we use multiple criteria combined with weighting factors arisen from the pairwise comparison. Necessary calculations are implemented in a Microsoft Excel file. On this basis, HRC-based application scenarios for efficient manufacturing are conceptualized, focusing mainly on pre-assembly and module-assembly. Concerning final assembly, only qualitative statements are made, as the increased complexity of these workplaces requires more extensive examination. Finally, the developed methodology and some of the scenarios are evaluated. We demonstrate that the efficiency of the widely manual production of wire harnesses can be enhanced by using HRC-enabled robots.