An integrated methodology for manufacturing systems design using manual and computer simulation

Traditional approaches to manufacturing systems design utilize a sequential procedure that focuses on production capacity requirements, with human operator task design developed late in the systems design phase. Implementing manufacturing systems in this way is difficult when operations management must design flexible and efficient processes, with an often incomplete understanding of how people can best perform within the system. This study developed an integrated methodology that uses both manual and computer simulations to evaluate system performance and ergonomic issues early in the system design process. Information about operator performance and ergonomics is obtained in the manual simulations, while estimates of operator utilization and system throughput is obtained through computer simulations. An iterative design process is used, with the results of manual and computer simulations informing each other during subsequent simulations. An industrial case study is presented here to demonstrate the effectiveness of this methodology. The results show that the methodology can be used to design manufacturing systems with significant savings in labor cost and improved manufacturing system flexibility.