In this paper we present a methodology which is being developed at the Institute for Mechanical Engineering Design. The aim of this methodology is to improve the assemblability of existing and future products. The key characteristic is that these improvements are based on the experience of the employees, who are involved in the assembly. Not only information about failures is used to improve the products but also the improvement potential within the current assembly system and products. This methodology is especially being developed for the manual single- and small batch assembly of big mechanical systems, which are designed with 3D-CAD. The methodology is based on current research activities in the field of design for assembly and a case study in a huge company, with the above mentioned constraints.

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