Assembly line design using a hybrid approach of lean manufacturing and balancing models

ABSTRACT This manuscript presents a method to design automotive production assembly lines that integrate lean manufacturing approaches and line balancing algorithms. In this work, we develop a clustering algorithm and task mutuality index for the assembly tasks to redesign and rebalance an assembly production line with a fixed layout and machinery. Moreover, we consider the product demand variability and the introduction of new product models. This paper describes the current and the future states of an automotive engines assembly production line using quantitative performance parameters and assembly tasks content flow charting, along with the analysis and results obtained from the proposed approach. The results show a reduction in required modeling and optimization efforts and a reduction in the required time to generate a feasible redesign of an assembly line while reaching the required takt time based on the demand forecast