The intelligent production line configuration strategy

Establishing an intelligent production line with high flexibility entails significant expenses, thereby strategic decision-making regarding the utilization of labor flexibility in the production line configuration becomes crucial for the success of a smart factory. This study considers two predominant production line configuration strategies in a production environment characterized by multi-variety and small-batch orders: (1) a double-line configuration strategy , where a fully automated intelligent production line focuses on producing relatively standardized products, while a manual production line is dedicated to crafting personalized products. We obtain optimal work allocation under this strategy. (2) a line-changeover configuration strategy , characterized by a single flexible production line where machine-driven tasks are automatically executed. Manual intervention is only required during line changeovers and setups between different product types. A comparative cost analysis between these two configuration strategies reveals that, for production batch size exceeding a batch threshold, the line-changeover strategy outperforms the double-line strategy. Moreover, if a square root rule is satisfied, the line-changeover strategy consistently outperforms the double-line strategy. Notably, investments directed towards setup reduction prove instrumental in reducing production costs and reducing the batch threshold, thereby amplifying the advantages of the line-changeover strategy. The future comparative advantage of these two configuration strategies is contingent upon ongoing technological developments. • This study compares two production line configuration strategies—double-line configuration (DLC) and line-changeover configuration (LCC). • The DLC strategy optimally allocates work between a fully automated intelligent production line and a manual line. • The LCC strategy outperforms the DLC strategy when batch size exceeds a critical threshold. • Investments in setup reduction significantly enhance the cost-efficiency of the LCC strategy, reducing the batch threshold.