Abstract
The ALPACA line balancing system is an interactive computer-based system for the planning and control of assembly lines upon which mixed models with a large option mix are to be assembled. The ALPACA system facilities the assignment of work to operators along the assembly line and provides immediate evaluations of the effects of the assignment of work. Work is assigned and initially evaluated on the basis of forecasted model mix and option mix percentages. The operator's work assignment is further evaluated by passing an actual vehicle build sequence of models complete with all specified options past the operation (via a simulation) to highlight any extreme overcycle or idle conditions which are not apparent from average values based on the forecasted model mix and option mix percentages. ALPACA gives the industrial engineer and the line supervisor, working together as a team, the ability to balance an assembly line quickly and react rapidly to product engineering changes and/or schedule changes.
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