The ongoing transition towards electro-mobility requires an increased reactivity and reconfigurability in automotive assembly. However, the traditional line assembly, which is characterized by rigid cycle times and linear product flow, has already been pushed to its flexibility limits. Drivers are the increase of product changes, variants and derivatives within assembly lines. To further increase reactivity and reconfigurability, matrix structured assembly configurations are a possible solution. Several studies highlight the theoretical advantages, but it has not been applied and validated in industrial use-cases, due to the high transformational gap between line and matrix configurations. In contrast, segment-wise line-less structures show a high potential for this.

A use-case oriented approach improves reactivity and reconfigurability by implementing an agile hybrid assembly system that combines the advantages of line and matrix structured (also referred to as line-less) assembly systems and offers a lower investment threshold. Three fields of action are presented: The first consists of flexible planning and control software modules. Within the planning phase, an automated scenario analysis is performed for optimization by applying simulations. During the production phase, the simulated model is re-used for the operation of a dynamical multi-agent manufacturing execution system with online scheduling algorithms. The second field of action deals with reconfigurable infrastructures, which comprises short-term dispatching intralogistics and a flexible layout, facilitated by AGV transport routes and reconfigurable self-adaptive workstations. The third field of action comprises a system model that is an underlying fully integrated digital twin. Control interfaces integrate the infrastructure into the manufacturing execution system to enable rapid system changes.

The presented hybrid system contributes to the design of future assembly systems by showing which aspects of line and matrix configuration can be combined to have a beneficial impact on a broad spectrum of production scenarios. By considering all relevant fields of action in a holistic way and by analyzing a hybrid configuration, the arising challenges for producing companies are addressed in a practical and functional manner.