View in EDS HTML Full Text PDF Full Text

Comparing fixed and walking worker strategies: design implications of individual worker efficiency on assembly line performance.

Saved in:
Bibliographic Details
Title: Comparing fixed and walking worker strategies: design implications of individual worker efficiency on assembly line performance.
Authors: Catalano, Francesca1 (AUTHOR) francesca.catalano.2@phd.unipd.it, Zennaro, Ilenia1 (AUTHOR), Berti, Nicola1 (AUTHOR), Persona, Alessandro1 (AUTHOR)
Source: International Journal of Production Research. Dec2025, Vol. 63 Issue 23, p9089-9111. 23p.
Subjects: Assembly line methods, Simulation methods & models, Labor productivity, Productivity accounting, Workforce planning, Decision support systems
Abstract: Human workers are essential in modern assembly systems, enabling flexibility, reconfigurability, and efficient resource utilisation while minimising costs. However, high workforce turnover and heterogeneity in individual skills and efficiency make it challenging to meet production targets effectively. Fixed Worker Assembly Line (FWAL) and Walking Worker Assembly Line (WWAL) represent two alternative workforce strategies to handle variations in production volume and mix. Current literature mainly proposes comparison analyses focusing on productivity assets, whereas workforce different efficiency levels have been rarely integrated in comparative models. This study investigates the suitability of these strategies based both on production characteristics and worker efficiency through the simulation of multiple scenarios, considering factors such as productivity rate, workstation layout, assembly time unbalancing, moving times, buffer capacity, and worker efficiency. Results show that mixed-model assembly lines with parallel stations and walking workers (MMAL-PSWW) perform best in environments with high worker heterogeneity, low ideal productivity rates, and significant system unbalancing. The key outcome of this research is a decision tree model that serves as a practical decision-support tool, offering clear guidelines to help managers select the most effective assembly line design under varying operational conditions. Highlights Exploring the comparison between fixed worker and walking worker strategies in assembly system, considering real-world constraints. Introducing a simulation approach that incorporates multiple factors influencing system performance, with particular emphasis on variables related to individual worker efficiency. Providing decision-makers with a graphical decision support tool to evaluate the impact of worker efficiency on assembly line strategy optimisation. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Production Research is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
Full text is not displayed to guests.
FullText Links:
  – Type: pdflink
Text:
  Availability: 1
Header DbId: egs
DbLabel: Engineering Source
An: 189849849
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
IllustrationInfo
Items – Name: Title
  Label: Title
  Group: Ti
  Data: Comparing fixed and walking worker strategies: design implications of individual worker efficiency on assembly line performance.
– Name: Author
  Label: Authors
  Group: Au
  Data: <searchLink fieldCode="AR" term="%22Catalano%2C+Francesca%22">Catalano, Francesca</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> francesca.catalano.2@phd.unipd.it</i><br /><searchLink fieldCode="AR" term="%22Zennaro%2C+Ilenia%22">Zennaro, Ilenia</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Berti%2C+Nicola%22">Berti, Nicola</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Persona%2C+Alessandro%22">Persona, Alessandro</searchLink><relatesTo>1</relatesTo> (AUTHOR)
– Name: TitleSource
  Label: Source
  Group: Src
  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Production+Research%22">International Journal of Production Research</searchLink>. Dec2025, Vol. 63 Issue 23, p9089-9111. 23p.
– Name: Subject
  Label: Subjects
  Group: Su
  Data: <searchLink fieldCode="DE" term="%22Assembly+line+methods%22">Assembly line methods</searchLink><br /><searchLink fieldCode="DE" term="%22Simulation+methods+%26+models%22">Simulation methods & models</searchLink><br /><searchLink fieldCode="DE" term="%22Labor+productivity%22">Labor productivity</searchLink><br /><searchLink fieldCode="DE" term="%22Productivity+accounting%22">Productivity accounting</searchLink><br /><searchLink fieldCode="DE" term="%22Workforce+planning%22">Workforce planning</searchLink><br /><searchLink fieldCode="DE" term="%22Decision+support+systems%22">Decision support systems</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Human workers are essential in modern assembly systems, enabling flexibility, reconfigurability, and efficient resource utilisation while minimising costs. However, high workforce turnover and heterogeneity in individual skills and efficiency make it challenging to meet production targets effectively. Fixed Worker Assembly Line (FWAL) and Walking Worker Assembly Line (WWAL) represent two alternative workforce strategies to handle variations in production volume and mix. Current literature mainly proposes comparison analyses focusing on productivity assets, whereas workforce different efficiency levels have been rarely integrated in comparative models. This study investigates the suitability of these strategies based both on production characteristics and worker efficiency through the simulation of multiple scenarios, considering factors such as productivity rate, workstation layout, assembly time unbalancing, moving times, buffer capacity, and worker efficiency. Results show that mixed-model assembly lines with parallel stations and walking workers (MMAL-PSWW) perform best in environments with high worker heterogeneity, low ideal productivity rates, and significant system unbalancing. The key outcome of this research is a decision tree model that serves as a practical decision-support tool, offering clear guidelines to help managers select the most effective assembly line design under varying operational conditions. Highlights Exploring the comparison between fixed worker and walking worker strategies in assembly system, considering real-world constraints. Introducing a simulation approach that incorporates multiple factors influencing system performance, with particular emphasis on variables related to individual worker efficiency. Providing decision-makers with a graphical decision support tool to evaluate the impact of worker efficiency on assembly line strategy optimisation. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Production Research is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
PLink https://search.ebscohost.com/login.aspx?direct=true&site=eds-live&db=egs&AN=189849849
RecordInfo BibRecord:
  BibEntity:
    Identifiers:
      – Type: doi
        Value: 10.1080/00207543.2025.2533520
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 23
        StartPage: 9089
    Subjects:
      – SubjectFull: Assembly line methods
        Type: general
      – SubjectFull: Simulation methods & models
        Type: general
      – SubjectFull: Labor productivity
        Type: general
      – SubjectFull: Productivity accounting
        Type: general
      – SubjectFull: Workforce planning
        Type: general
      – SubjectFull: Decision support systems
        Type: general
    Titles:
      – TitleFull: Comparing fixed and walking worker strategies: design implications of individual worker efficiency on assembly line performance.
        Type: main
  BibRelationships:
    HasContributorRelationships:
      – PersonEntity:
          Name:
            NameFull: Catalano, Francesca
      – PersonEntity:
          Name:
            NameFull: Zennaro, Ilenia
      – PersonEntity:
          Name:
            NameFull: Berti, Nicola
      – PersonEntity:
          Name:
            NameFull: Persona, Alessandro
    IsPartOfRelationships:
      – BibEntity:
          Dates:
            – D: 01
              M: 12
              Text: Dec2025
              Type: published
              Y: 2025
          Identifiers:
            – Type: issn-print
              Value: 00207543
          Numbering:
            – Type: volume
              Value: 63
            – Type: issue
              Value: 23
          Titles:
            – TitleFull: International Journal of Production Research
              Type: main
ResultId 1