Conceptual Design of a Next-Generation Wire Harness Assembly Workstation for Industry 5.0

Abstract

This thesis presents a conceptual design for the next generation of wire harness assembly workstations at Volvo Cars. With the manufacturing industry shifting toward Industry 5.0, the primary objective of this research was to develop a realistic, efficient, and flexible assembly solution capable of being implemented within a 5 to 10-year timeframe. Through a comprehensive literature review, interviews with industry stakeholders, and a detailed requirement analysis, this study evaluates the integration of Automated Guided Vehicles (AGVs) and collaborative robots (cobots) as a viable strategy to enhance production performance. The proposed solution emphasizes a gradual transition toward increased automation, where cobots and AGVs are integrated directly into the wire harness workstation to support operators, improve ergonomics, and stabilize material flow. The simulation assessment was used to evaluate the proposed workstation layout, movement sequences, approximate cobot reach, and compatibility with the existing line speed. In addition, the concept includes an AI-based automated quality control system integrated into the wire-harness workstation. The system is intended to support inspection of routing, component presence and variant correctness immediately after assembly tasks are completed. The findings suggest that the role of the human operator will evolve from performing repetitive manual labor to assuming more high-level responsibilities, such as system management, operational oversight and complex problem-solving. By retaining human expertise for scenarios requiring specialized judgment, the proposed design achieves a balanced synergy between advanced automation and human-centric manufacturing. This research provides a structured roadmap for Volvo Cars to modernize its production facilities, ensuring long-term competitiveness and operational efficiency