An approach to scalability and line balancing for reconfigurable manufacturing systems

Line balancing has been an important technique for manufacturing system design, because a completely balanced system can provide maximum resource utilization at the designed capacity. However, even if a system is completely balanced, it still has capacity waste when the entire product life cycle is considered, because real production is often significantly less than capacity. Avoiding this mismatch requires scalable systems such as reconfigurable manufacturing systems (RMSs) to meet changing product demand. Stage paralleling is suggested as an approach to scalability for RMSs. By comparing the economic feasibility of such manufacturing systems with completely balanced transfer line systems with respect to station cost, it is shown that line balancing is not necessarily desirable with this approach. The effect of station cost differences for unbalanced systems is also considered.