Design evaluation of automated manufacturing processes based on complexity of control logic

Complexity continues to be a challenge in manufacturing systems, resulting in ever-inflating costs, operational issues and increased lead times to product realisation. Assessing complexity realizes the reduction and management of complexity sources which contributes to lowering associated engineering costs and time, improves productivity and increases profitability. This paper proposes an approach for evaluating the design of automated manufacturing processes based on the structural complexity of the control logic. Six complexity indices are introduced and formulated: Coupling, Restrictiveness, Diameter, Branching, Centralization, and Uncertainty. An overall Logical Complexity Index (C-L) which combines all of these indices is developed and demonstrated using a simple pick and place automation process. The results indicate that the proposed approach can help design automation logics with the least complexity and compare alternatives that meet the requirements during initial design stages. (C) 2016 The Authors. Published by Elsevier B.V.