Perceived production complexity – understanding more than parts of a system

To successfully manage today’s complex production systems it is essential to study operators’ perception of the system. The paper presents perceived production complexity assessed at seven manufacturing companies with the CompleXity Index (CXI) method. While other methods have measured product variants, layout, work content, tools and information items, CXI combines them into three areas. These three complexity areas (Station design, Work variance and Disturbance handling) help to create an understanding of the complex system by visualising how they contribute to complexity, and show the need to support the operators’ ability to handle the varying work