Layout considerations in assembly line design

The authors address the problem of determining the optimal amount of workspace in assembly lines when the number of variations in the product is very large. This situation arises, for example, in automotive assembly plants which assemble the product to order (as is the case in most domestic automotive assembly plants in North America). The authors describe how the problem is related to a class of queueing systems. Analytical methods are developed to estimate the effects of workspace size on labour, quality, and warranty costs. The approach presented here can be used to study the trade-off between various related costs. The authors illustrate the concepts with a numerical example. Future research directions are provided.