The impact of unequal processing time variability on reliable and unreliable merging line performance

Research on merging lines is expanding as their use grows significantly in the contexts of remanufacturing, reverse logistics and developing economies. This article is the first to study the behavior of unpaced, reliable, and unreliable merging assembly lines that are deliberately unbalanced with respect to their coefficients of variation (CV). Conducting a series of simulation runs with varying line lengths, buffer storage capacities and unbalanced CV patterns delivers intriguing results. For both reliable and unreliable lines, the best pattern for generating higher throughput is found to be a balanced configuration (equal CVs along both parallel lines), except for unreliable lines with a station buffer capacity of six. In that case, the highest throughput results from the descending configuration, i.e. concentrating the variable stations close to the beginning of both parallel lines and the steady stations towards the end of the line. Ordering from the least to most steady station also provides the best average buffer level. By exploring the experimental Pareto Frontier, this study shows the combined performance of unbalanced CV patterns for throughput and average buffer level. Study results suggest that caution should be exercised when assuming equivalent behavior from reliable and unreliable lines, or single serial lines and merging lines, since the relative throughput performance of some CV patterns changed between the different configurations

The operating behaviour of unbalanced, unpaced merging assembly lines

Unbalanced assembly line research has grown in importance because of its increasing applications in emerging economies, reverse logistics and remanufacturing. This paper examines the performance of numerous simulated patterns for reliable unbalanced manual merging assembly lines. The contribution of this study to the literature is that imbalance does not always negatively impact efficiency and that it can improve merging line performance when compared to a corresponding balanced merging line. The best performance was found to be a balanced line configuration and a monotone decreasing order for both parallel merging lines, with the former generally resulting in a lower throughput and the latter resulting in a lower average buffer level than that of a balanced line