Modelling randomness of a manual assembly system with walking worker

Most proposed approaches for modelling and simulation of an assembly production line have focused on conventional assembly lines where one (or more) stationary worker stays at a given station to complete a repetitive assembly operation and when this operation is accomplished, the assembled part is transferred to another worker at the next station for the next assembly operation. This paper presents an investigation of a linear walking worker assembly line where one worker walks along the line to complete the assembly of a product from start to finish. The study was carried out based on a real job shop environment with a demand-pull production control system. The randomness of walking worker activities was modelled using a proprietary simulation package. The paper discusses several issues which may assist in the early stages of designing a linear walking worker line.