The Use of a Complexity Model to Facilitate in the Selection of a Fuel Cell Assembly Sequence

Various tools and methods exists for arriving at an optimised assembly sequence with most using a soft computing approach. However, these methods have issues including susceptibly to early convergence and high computational time. The typical objectives for these methods are to minimise the number of assembly change directions, orientation changes or the number of tool changes. This research proposes an alternative approach whereby an assembly sequence is measured based on its complexity. The complexity value is generated using design for assembly metrics and coupled with considerations for product performance, component precedence and material handling challenges to arrive at a sequence solution which is likely to be closest to the optimum for cost and product quality. The case presented in this study is of the assembly of a single proton exchange membrane fuel cell. This research demonstrates a practical approach for determining assembly sequence using data and tools that are used and available in the wider industry. Further work includes automating the sequence generation process and extending the work by considering additional factors such as ergonomics.