Process time distribution simulation in robotic assembly line balancing

Dawid Stade, Jan Michael Spoor, Martin Manns and Jivka Ovtcharova

International Journal of Production Research, 2025, vol. 63, issue 10, 3467-3484

Abstract: Feedback control systems utilised in car body construction cause process time variance when compensating for external disturbances. By considering these in robotic assembly line balancing, the risk of cycle time violations can be controlled. This requires knowledge of the underlying process time distributions, which are not known in advance. Therefore, a simulation method is proposed to assess the impact of varying process time distributions on the balancing of robotic assembly lines. The initial step involves acquiring the process times of existing production processes. In the subsequent simulation, these are randomly and repeatedly selected as substitutes for the process times in the balancing of a new robotic assembly line. The impact of process time distribution variations on the result is investigated, and a single solution can be selected. The proposed method is evaluated based on the balancing of a robotic assembly line for a body-in-white rear compartment. Results are compared to normally distributed process times, which is a common assumption for modelling uncertain process times. Both approaches are evaluated utilising actual process time distributions. It is demonstrated that the proposed method yields fewer and less severe underestimations of cycle times, thereby reducing the number of uncontrolled violations of cycle times.

Date: 2025
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DOI: 10.1080/00207543.2024.2416570

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