Optimization of multiple panel fitting in automobile assembly

A systematic approach is presented to obtain improved panel fit quality through the use of an optimum panel fitting strategy. The objective of the optimal panel fitting strategy is to determine the location of the panels on the automobile body such that the gap and flush variation of the panel fit are minimized. This approach uses measurement data from both the panels and the body-in-white (BIW) to determine the optimum position of multiple panels in an automobile body opening. First, some indices are defined to quantify the quality of a panel fit. Second, the sources of variation in the gap and flush are presented. Then the multiple panel fitting problem is formulated into a constrained optimization model. The effects of the optimization model and algorithm by reducing the within-car gap and flush variation on average by 24,3 % and by as much as 43,4 % in the case study presented.