Design for mixed model final assembly line (DfMMFAL): a new tool for assembly interface identification based on assembly process planning

Purpose This paper aims to fulfil a need to identify assembly interfaces from existing products based on their Assembly Process Planning (APP). It proposes a tool to identify assembly interfaces responsible for reused components integration. It is integrated into a design for mixed model final assembly line approach by focusing on the identification of assembly interfaces as a generic tool. It aims to answer the problem of interfaces’ identification from the APP. Design/methodology/approach A tool is developed to identify assembly interfaces responsible for reused component integration. It is based on the use of a rule-based algorithm that analyses an APP and then submits the results to prohibition lists to check their relevance. The tool is then tested using a case study. Finally, the resulting list is subjected to a visual validation step to validate whether the identified interface is a real interface. Findings The results of this study are a tool named ICARRE which identify assembly interfaces using three steps. The tool has been validated by a case study from the helicopter industry. Research limitations/implications As some interfaces are not contained in the same assembly operations and therefore, may not have been identified by the rule-based algorithm. More research should be done by testing and improving the algorithm with other case studies. Practical implications The paper includes implications for new product development teams to address the difficulties of integrating reused components into different products. Originality/value This paper presents a tool for identifying interfaces when sources of knowledge do not allow the use of current methods.