Modular matrix assembly

© Fraunhofer IPA / Rainer Bez
Assembly without production lines or cycle times: Fraunhofer IPA designs productive and versatile matrix assembly systems.

Today's assembly systems have to cope with huge challenges: high numbers of different products, uncertain quantity forecasts and a fluctuating mix of variants make line assembly inefficient and require highly-complex control technologies. Modular matrix assembly systems consisting of freely-interlinked stations are becoming established as a competitive, alternative assembly structure in a volatile environment.

The matrix provides new degrees of freedom when it comes to designing, planning and controlling assembly systems. Common planning methods in lean line design cannot be transferred 1-to-1 to matrix assembly. The potential of matrix production goes far beyond simply separating previously-linked stations and transferring special equipment to secondary stations. Fraunhofer IPA has developed process-oriented planning methods to design and convert your assembly system as a matrix, taking into account your specific conditions.

Analysis of the potential of matrix assembly

  • Assessing the productivity potential, evaluating profitability and estimating the investment costs of matrix assembly for a given production range and specific conditions
  • Comparing matrix assembly and conventional assembly structures (such as assembly lines, workshop assembly, single workstation assembly)
  • Verifying the suitability of products and processes for matrix assembly on the basis of use cases

Matrix assembly design

  • Planning and designing the matrix assembly system according to capacities
  • Workplace design
  • Choosing the appropriate material supply strategy, designing the logistics system for material supply and material flow, as well as selecting logistics equipment
  • Designing the planning and control logic for the matrix production system

Transformation support

  • Developing a matrix transformation roadmap
  • Devising a migration strategy, planning implementation, cardboard engineering
  • Validating the planning solution via material flow simulation
  • Start-up support

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