Mixed model assembly alternatives for low-volume manufacturing: The case of the aerospace industry

In this paper, we investigate new alternatives for mixed model assembly in low-volume manufacturing environments where the efficient utilization of labor and/or machinery presents significant challenges. A total of four models are developed for evaluating cycle time and worker allocation alternatives with respect to labor and inventory holding costs. These models include one linear and two nonlinear programs, which are formulated to evaluate constant and variable cycle time policies. A separate model is used to evaluate the benefits associated with allocating workers to different stations along the assembly line under different cycle time alternatives. We successfully applied these models to an airplane assembly process characterized by low-volume manufacturing.