Mix Model Balancing with the Floating Operators

Mixed-model production lines enable automakers to reduce capital costs by building multiple vehicle types on a single line but create challenges in balancing workloads and maintaining efficiency. This study examines the use of floating operators as a flexible strategy to manage workload variability in a brownfield automotive plant producing three models—Sedan, CUV, and SUV—on a shared assembly line. A discrete-event simulation built in Siemens Tecnomatix evaluated performance across different sequencing strategies, with and without floaters. Key metrics included throughput, operator utilization, and line efficiency. Results show that introducing floaters significantly reduced bottlenecks and improved utilization balance across stations, while optimized model sequencing further enhanced overall line performance. The findings confirm that combining flexible labor allocation with strategic sequencing offers a practical, cost-effective approach to improving productivity and stability in mixed-model automotive assembly operations.