An Integrated Layout and Resource Planning Approach for Assembly Lines

Balancing assembly lines has drawn significant research interest over decades due to its vital impact on throughput without adding extra resources. This paper targets production facilities operating multiple identical assembly lines, particularly those facing challenges due to variable task durations across workstations. We propose a methodology for layout planning that prioritizes system-wide balance over independent line balance, leveraging simulation techniques. Our methodology involves removing workstations with long task durations from individual lines and centralizing them to serve all lines. In a real-world case study, the proposed methodology boosts throughput by up to 12% by optimizing the utilization of existing resources.