Simulation-based optimization of personnel assignment planning in sequenced commercial vehicle assembly: A software tool for iterative improvement

This paper presents a simulation-based planning software for high complexity production settings which currently undergoes first real-data industry application tests in commercial vehicle assembly. The system will also be applicable in other industries with a sufficiently high number of products and variants. The solution enables the forecasting of required personnel and temporary additional workers (“floaters”) for every cycle at the production line. It periodically collects process times, sequence and feature data for the vehicles. The cumulated workload is calculated under consideration of flexibilities. A web-based user interface enables to set and change reference data, define process simulations and to compile diagrams and charts for the analysis of the results of the different simulation runs. Various filters as to time periods, vehicle types or feature variants allow the planner a target-oriented analysis and provide feedback for improving production line tacting. Finally, some qualitative results of a first industry test in commercial vehicle assembly give feedback about the usability of existing analytical features and desirable additional features.