Investigation of the workforce effect of an assembly line using multi-objective optimization

ABSTRACT The aim of industrial production changed from mass production at the beginning of the 20th century. Today, production flexibility determines manufacturing companies' course of action. In this sense, Volvo Group Trucks Operations is interested in meeting customer demand in their assembly lines by adjusting manpower. Thus, this investigation attempts to analyze the effect of manning on the main final assembly line for thirteen-liter heavy-duty diesel engines at Volvo Group Trucks Operations in Skövde by means of discrete-event simulation. This project presents a simulation model that simulates the assembly line. With the purpose of building the model data were required. One the one hand, qualitative data were collected to improve the knowledge in the fields related to the project topic, as well as to solve the lack of information in certain points of the project. On the other hand, simulation model programming requires quantitative data. Once the model was completed, simulation results were obtained through simulation-based optimization. This optimization process tested 50,000 different workforce scenarios to find the most efficient solutions for three different sequences. Among all results, the most interesting one for Volvo is the one which render 80% of today’s throughput with the minimum number of workers. Consequently, as a case study, a bottleneck analysis and worker performance analysis was performed for this scenario. Finally, a flexible and fully functional model that delivers the desired results was developed. These results provide a comparison among different manning scenarios considering throughput as main measurement of the main final assembly line performance. After analyzing the results, system output behavior was revealed. This behavior allows predicting optimal system output for a given number of operators.