Conceptual modelling of a flexible simulation model for determining operator headcount

With the conception of Industry 5.0, a reinvigorated focus is being placed on human effort (operators) in the industrial landscape to enhance productivity, increase reliability, and maintain competitiveness. However, the integration of automation and robotics with operators brings significant new challenges in workforce planning, particularly in determining the optimal operator headcount required. Efficient allocation of human resources becomes complex as manual, collaborative, semi-automated, and fully automated tasks coexist within the same operational framework. Due to this variation, multiple models are typically needed to simulate each scenario. To reduce the need for multiple simulation models, this research aims to create one model that can flexibly adjust to the parameters set by the user (here defined as a flexible simulation model). This allows the user the ability to rapidly and flexibly model the work area, product, number of machines, the type of material transportation system, and more. This paper presents a conceptual approach to building a flexible simulation model for the estimation of operator headcount. The primary aim is to establish a methodology for developing a single adaptable simulation model capable of handling the complexity and variability of production parameters. The study explores the theoretical advantages of flexible simulation models, such as improved scalability, reduced development time, and easier scenario testing, as well as potential disadvantages like increased model complexity and validation challenges. Furthermore, in future work, a deeper dive into validating such a model will be performed.