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Reconfigurable manufacturing systems have been proposed over the last decades to deal with mass-customization problems and volatile markets. Issues regarding the physical design, control, or scheduling of these systems have been studied intensively but very few studies have investigated inherent safety problems. Yet this issue is crucial for reconfigurable assembly systems where manual and robotized workstations must cohabit. The present paper first presents the main safety issues inherent to this new type of manufacturing system. A methodological approach based on adaptable solutions (e.g. safety plans, movable barriers, and safety laser scanners) and comprising two phases (‘offline’ and ‘online’) is then proposed to address in a short time the previous issues. At each step of the ‘offline’ phase, dedicated software assists the safety manager (in charge of and responsible for safety) to design a ‘safe’ reconfigurable manufacturing system. Once this design is validated by the safety manager, the ‘online’ phase of the methodology is deployed.

Proposition of a software-assisted methodology to solve safety issues in reconfigurable assembly systems in a short time