New Approach for Detecting Variability in Industrial Assembly Line Balancing Based on Multi-Criteria Analysis

This paper focuses on the complex dynamics that concern assembly line balance in the context of mass customization within manufacturing. In fact, the increase in demand for customized products has heightened the complexities associated with achieving optimal efficiency, productivity, product quality, and customer satisfaction. The research proposes a multi-criteria analysis of statistical methods to determine the fluctuation of parameters affecting the state of balance of an assembly line. A 3D matrix model is suggested to analyze the parameters managing the assembly line. This representation is executed using the MATLAB R2024b tool, and a methodology for finding the variability of parameters affecting balance through statistical approaches is proposed. We observed that changes in parameters such as task times, worker efficiency, or material flow led to significant changes in the line’s overall balance. As a result, static balancing becomes inadequate to deal with the complexities introduced by these highly variable parameters. The novelty of this paper consists of the innovative integration of multi-criteria statistical analysis and 3D matrix modeling to detect parameter variability and optimize assembly line balancing. Conventional static approaches are often unable to capture the process-dynamic aspect of modern manufacturing. This work presents a systematic methodology capable of identifying, quantifying, and moderating the variability of key operating parameters. This methodology, carried out using MATLAB-based simulations, is based on principal component analysis (PCA) and correlation analysis to detect critical factors influencing balancing efficiency. By structuring assembly line parameters in a 3D matrix representation, this research gives a holistic, data-based method for improving decision-making in balancing procedures. The research goes beyond theoretical modeling by applying the approach to a real automotive assembly line, validating its effectiveness and demonstrating its practical applicability in industrial conditions.