A simulation approach to evaluating assembly line balancing solutions

Abstract

The design of assembly lines For mass production and, in particular, the task of assigning and balancing work elements between stations on an assembly line, has frequently relied upon the assumption that the problem conditions defined at the balancing stage will eventually become the operating conditions throughout the life of the assembly line. In many assembly line operations, especially those involving mixed-model or multi-model production, the acceptance of this assumption of continuity of problem conditions can lead to the introduction of assembly line designs that subsequently prove inefficient under actual operational conditions. The case therefore arises for an approach capable of examining this likely variation between the estimated balancing conditions and actual operating conditions (i.e. an approach to assessing assembly line versatility). Furthermore, there would be a distinct benefit when the examination of line versatility is undertaken at the assembly line design stage. Within this paper a simulation model, part of an integrated balancing and evaluation system capable of achieving this task, is described. Use of the simulation software is demonstrated by examples drawn from a test programme of over 200 simulations and summary conclusions are drawn from use of this simulation approach.