Impact of work teams: a comparison study of assembly cells and assembly line for a variety of operating environments

This research compares assembly lines with different cellular, team working environments. Organization of an assembly system using cells requires worker flexibility where each worker is allowed to help his or her co-workers in the same cell and often to undertake a number of different tasks within the cell. We compare two different cellular systems with an unpaced, serial assembly line. The manufacturing systems are initially compared through an exploratory Markovian approach. Subsequently, the relative performance levels of the systems are examined across a variety of operating environments using simulation models. Operating environments vary based on shop size, setup times and processing time variances. The results indicate the general superiority of the cellular systems over the assembly line. However, some interesting observations are drawn for cases where the assembly line outperforms the cells. One of the cases is where workers realize substantial benefits in terms of performing their tasks in less time due to specialization on the tasks. The other scenario is where working in teams make the overall completion of the tasks more inefficient compared to working individually. Specific cross-over points are analyzed where the assembly lines start performing better than the assembly cells under these scenarios. The conclusions highlight guidelines for practicing managers on the most appropriate system under a given set of operating conditions.