Design and Development of Semi-Automated Assembly Frameworks for Enhanced Ergonomics, Precision, and Repeatability in Automotive Component Manufacturing

The increasing complexity of automotive components demands assembly systems that balance precision, speed, and human factors. Semi-automatic assembly machines integrate human skills with mechanized assistance, enabling efficient and accurate production while improving operator ergonomics. This paper presents a systematic approach to the design and development of semi-automated assembly frameworks, focusing on key objectives: minimizing cycle time, enhancing repeatability, reducing errors, and incorporating robotics with robust safety systems. A detailed case study on the assembly of a powered window regulator illustrates the application of these frameworks, highlighting the challenges of handling precise components and optimizing workflow. The study explores the integration of advanced technologies in semiautomation, including ergonomic workstation design, modular assembly stations, and safety-compliant robotic interfaces. Emphasis is placed on prototyping methodologies and iterative design processes to ensure consistent part quality and reduced scrap rates. Results demonstrate that thoughtful integration of human and machine elements can significantly improve production efficiency, operational safety, and repeatability. This research provides a structured framework for designing semiautomated assembly systems, offering practical insights for industrial implementation in the automotive sector and contributing to the advancement of hybrid human-machine manufacturing technologies.