Optimal planning and scheduling of assembly lines†

Abstract

This paper explores the economic conditions under which single-model assembly lines are operated in a batch mode (through intermittent manufacture at higher production rates) rather than by the traditional method of continuous production at the demand rate. A model for optimizing the ‘cycle time, station number’ combination is developed through consideration of five factors: the learning, inventory, setup, balancing and facility costs. Economic justification for operating in a batch mode was found for total demands ranging from 20 to 4000 assembled products which is expected to include a sizable percentage of the total products manufactured in industralised countries each year. Greatest savings occur for total demands in the order of 1000 products.

Notes

†This research was supported by the Technion's V.P.R. Fund—Y. Apter Research Fund.