Hypothesis test of a new line balancing approach with dynamic allocation of assembly operations

Sammanfattning: Assembly lines are no longer systems designed to produce as much as possible at the lower cost. Nowadays several factors such as mass customization and variation in demand have led the manufacturers to consider the flexibility of the assembly systems as one of the most important facts to take into account when designing an assembly line. In this context, this study attempts to test a new paradigm of the workload balance, which is based on a dynamic allocation of the assembly operations. In order to test the hypothesis, a real assembly system of engines has been used as a base model to implement the new approach. The work developed, uses the simulation as a means to carry out the study, which has required the development of several simulation scenarios. The hypothesis has been studied from two different approaches; on one hand a total dynamic allocation of assembly operations, which was expected to cause a wide operational range of the stations. On the other hand, the second approach implements a flow control which aims to reduce the operational range and workload fluctuations. The results obtained show a significant improvement of the system performance in comparison with the current assembly line. It has been found that any improvement implemented in the system is directly reflected in the total performance of the line, regardless if the improvement is made in a system constraint. Moreover, the results have proven a better response of the system to changes in the frequency of models production.  Finally, based on the results, this study suggests several paths of future work in order to acquire the needed information to implement the hypothesis in the real world context.