We investigate in this paper alternative configuration choices of serial assembly lines. In particular, we analyze the impact on throughput and work-in-process inventory levels from several design choices. These are the number of work-stations, tasks allocated to various stations and buffers between workstations. A simulation model is used to evaluate the sensitivity of various designs to variability in the operating environment arising due to process time variations (operator variability) as well as variations due to breakdowns and repair (machine variability). Insights of the tradeoffs for making capital investment and setting operating policies are also discussed.
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