Assessment of manual assembly complexity: a theoretical and empirical comparison of two methods

There are several theoretical methods for assessment of assembly complexity but there are few practically applicable methods. One of the methods, CompleXity Index (CXI), aims at assessing operators' perception of manual assembly complexity in running production. Another recently developed method, Basic Assembly Complexity (CXB) is intended for predictive assessment of basic manual assembly complexity in early product and production development. Both CXI and CXB aim to improve assembly conditions for operators, reduce assembly-related errors and the costs for corrective measures as well as increase assembly quality although in different ways and at different organisational levels and life cycle stages. The purpose of this study was to compare the two methods to obtain feedback and learn from operators experience in order to develop better predictive assessment criteria. The method comparison showed that about 50% of the CXB assessment approaches were similar to CXI but other covered different aspects. In comparison of the complexity values of the methods no significant results were obtained. However, some CXI issues that were not taken into account in CXB should be considered. CXB and CXI could be used in conjunction but further assessment criteria are probably needed.