Simulation-Based Optimization of Assembly Line Efficiency Through Intelligent Operator Rotation and Resource Utilization Balancing

This paper addresses the use of discrete-event simulation as a tool for optimizing the production process of an assembly line and identifying the potential for improving production efficiency. A digital model of the manufacturing system was developed in the FlexSim simulation environment based on real production data, technological operation sequences, and statistically defined cycle times. The model was designed to accurately represent real production conditions, including control logic, resource interactions, and material flow. The simulation results were analyzed using graphical and quantitative reports, which enabled the identification of production bottlenecks and inefficient resource utilization. Based on the obtained data, a process optimization strategy was proposed in the form of intelligent operator rotation between workstations to increase operator utilization and improve overall system efficiency. The proposed modifications were subsequently verified through simulation experiments, confirming the preservation of the required production capacity while improving the efficiency of human resource utilization. The findings confirm that simulation modeling represents an effective tool for the analysis, design, and verification of optimization measures, enabling the reduction in operational costs and risks associated with implementing changes in real manufacturing environments.