A computer simulation approach to evaluating assembly line balancing with variable operation times

Purpose - The purpose of this paper is to develop a computer simulation model to evaluate the bowl phenomenon and the allocation at the end of the line of stations with either greater mean operation times or higher variability of operation times. Design/methodology/approach - The model was developed on the basis of a realistic case problem and applied to a six-station assembly line. The evaluation criteria were the: minimization of the total elapsed time; maximization of the average percentage of working time; and minimization of the average time in the system. Findings - The performance of an assembly line with independently normally distributed operation times could be improved by applying the bowl phenomenon. The allocation of large operation mean times to stations located near the end of the line did not produce improved results. Instead a more balanced allocation proved to be more significantly effective. On the other hand, the assignment of larger variability of operation times to the stations near the end of the line improved the performance of the assembly line. Originality/value - The investigation contributed to the computer simulation approach to solving assembly line problems that dealt with the impact of normally distributed operation times on the bowl phenomenon and assembly lines with increasing mean operation times and higher variability of operation times at the end of the line of stations.