The assembly line is widely used in the manufacturing of products that involve tasks with defined and repetitive sequences. Its efficiency greatly impacts the overall manufacturing process, necessitating resource optimization. Balancing activities among workstations is a design challenge, especially in mixed-product assembly lines, due to significant variations in task durations and short-term changes in product sequencing. This paper introduces a balancing system that considers product sequencing effects on resource utilization. The system identifies specific sets of sequenced activities for each product type and operator, enhancing workstation flexibility. It employs balancing strategies utilizing a precedence diagram and a heuristic algorithm based on positional weights. Modeling and simulation are performed using Coloured Petri Nets. A case study of a truck assembly line in Brazil illustrates the main features of this approach. Simulation results demonstrate that it is possible to reduce dependent occupancy and sequencing, meet cycle time requirements, and achieve a 12.5% reduction in resource utilization while maintaining acceptable average occupancy, ultimately establishing a system beneficial for assembly line managers.
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