Design Synthesis Framework for Dimensional Management in Multistage Assembly System

This paper proposes a design synthesis framework for dimensional management in multistage assembly systems which integrate the critical design tasks: (1) Tolerance Optimization; (2) Multi-Fixture Layout Design; and, (3) Part-to-part Joint Design. The proposed framework is based on the development of: (1) a new hybrid Design Structure Matrix which integrates design tasks with design configurations of Key Control Characteristics, and which has the capability to model and analyze the interdependencies among design tasks and constraints; and (2) Task Flow Chain which represents the hierarchy of design tasks and is used to generate the sequence of design tasks. The proposed methodology is illustrated and validated in the process of designing configurations for automotive underbody subassembly.