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In the current era of Industry 4.0, the manufacturing industries are striving toward mass production with mass customization by considering human–robot collaboration. This study aims to propose the reconfiguration of assembly systems by incorporating multiple humans with robots using a human–robot task allocation (HRTA) to enhance productivity.

A human–robot task scheduling approach has been developed by considering task suitability, resource availability and resource selection through multicriteria optimization using the Linear Regression with Optimal Point and Minimum Distance Calculation algorithm. Using line-balancing techniques, the approach estimates the optimum number of resources required for assembly tasks operating by minimum idle time.

The task allocation schedule for a case study involving a punching press was solved using human–robot collaboration, and the approach incorporated the optimum number of appropriate resources to handle different types of proportion of resources.

This proposed work integrates the task allocation by human–robot collaboration and decrease the idle time of resource by integrating optimum number of resources.

The purpose of this paper is to investigate and quantify the impact of product complexity, including architectural complexity, on operator learning, productivity and quality performance in both assembly and disassembly operations. This topic has not been extensively investigated in previous research.

An extensive experimental campaign involving 84 operators was conducted to repeatedly assemble and disassemble six different products of varying complexity to construct productivity and quality learning curves. Data from the experiment were analysed using statistical methods.

The human learning factor of productivity increases superlinearly with the increasing architectural complexity of products, i.e. from centralised to distributed architectures, both in assembly and disassembly, regardless of the level of overall product complexity. On the other hand, the human learning factor of quality performance decreases superlinearly as the architectural complexity of products increases. The intrinsic characteristics of product architecture are the reasons for this difference in learning factor.

The results of the study suggest that considering product complexity, particularly architectural complexity, in the design and planning of manufacturing processes can optimise operator learning, productivity and quality performance, and inform decisions about improving manufacturing operations.

While previous research has focussed on the effects of complexity on process time and defect generation, this study is amongst the first to investigate and quantify the effects of product complexity, including architectural complexity, on operator learning using an extensive experimental campaign.