Human-robot activity allocation algorithm for the redesign of manual assembly systems into human-robot collaborative assembly

As a key and enabling technology of Industry 4.0, there is no doubt that manufacturing enterprises will benefit from the introduction of collaborative robots (cobots) in their production processes. A large part of collaborative applications will arise from the re-design of existing manual assembly workstations. For this reason, companies need methods and guidelines for the proper adoption of these systems. Thus, this work presents a systematic methodology for the static allocation of assembly tasks between the human and the robot by considering a human-centric approach and the requirements in terms of technical feasibility, safety and ergonomics, quality, and economics. The proposed approach will support the manufacturers in overcoming technical barriers related to the proper design of collaborative solutions and in the implementation of more sustainable, high-quality, and efficient manufacturing processes starting from manual assemblies. The methodology has been proven and validated in an industrial case study. Results show how the proposed algorithm can support companies in the parallel improvement of the operator’s working conditions as well as the company performance at the same time.