Industry 4.0 (I4.0) aims to diffuse new technologies in industrial world, especially in the manufacturing sector. The main components of the expected new industrial skills are related to the Industrial Internet of Things (IIOT), which incorporates a profound transformation of the digitalization and communication of the industrial shop floor. Assembly lines and assembly systems are a primary process for the manufacture of mechanical products, they are linked to the coupling of different parts. The rise of intelligence in I4.0 mechanical systems has facilitated real-time data access and ensured system interconnectivity through smart parts embedded in Assembly 4.0 (A4.0). But, it has increased the complexity of maintaining these assemblies. This has led to several challenges when performing a maintenance phase, the main factor is the wear parts access difficulties. To this end, a new Design For Selective Assembly and Disassembly process optimization (DFSA/D) approach is proposed in this paper, which focuses on studying and modifying the design architecture of already existing product or from design phase to facilitate access to wear parts and standardizing fasteners to reduce maintenance time and costs. To validate the proposed approach a mechatronic product ‘TurtleBot3Burger’ selective assembly and disassembly sequence is used as a case study.
