Bridging the automation gap in assembly: a comprehensive model for potential assessment and implementation

Even in the era of Industry 4.0 automation of assembly processes remains a significant challenge in modern manufacturing, particularly in industries with high product variability and complex assembly tasks. This paper addresses these challenges by presenting a novel, comprehensive approach to evaluate and implement automation in existing assembly processes. The study introduces a multi-criteria methodology integrating economic and technical factors for assessing automation potential, designed to be applicable across various manufacturing sectors. The study demonstrates how to systematically analyze automation opportunities and develop tailored solutions that balance technological feasibility with economic viability. The effectiveness of this methodology is validated through its application in an existing transmission assembly line. By first applying the developed evaluation model, the study identifies specific automation potentials. Based on these findings, an automation solution is then designed, showcasing how the proposed approach can be successfully implemented to enhance long-term competitiveness in complex manufacturing environments.