Optimization of Operator Allocation in a Large Multi-Product Assembly Shop through Integration of Computer Simulation and DEA by Incorporating Efficiency, Waste, Cost and Cycle Time

This study presents an integrated computer simulation and Data Envelopment Analysis (DEA) for optimum operator allocation in a large multi-product assemblyshop by incorporating cost, time, efficiency and waste. At first, computer simulation is used as an exquisite tool for modelingand analyzing the true performance of the system. Then, theoutputs of simulation in terms of efficiency, waste, cost, idle time and time in system are modeled by an input-orientedDEA. The purpose of this study is to find the optimal number of sub-station operators regarding to five objectives:maximizing efficiency and minimizing waste, cost, idle timeand total time in system. The results show that we must allocate certain operators to selected sub-stations to optimizethe results. This is the first study that concurrently incorporates efficiency, time, cost and waste for optimization ofoperators’ allocation in a large assembly shop. Therefore, the results of this study are more precise and reliable than previous studies because of concurrent considerations of time, cost, waste and efficiency