Strumenti per la progettazione di sistemi di assemblaggio flessibili che considerano la diversità degli operatori

The transformation of industrial systems is reshaping the role of manual assembly lines. Increasing demand for product customisation, compressed production cycles, and the spread of high-mix, low-volume manufacturing are exposing the limits of rigid automation and emphasising the importance of flexible, human-centred strategies. Rather than being displaced, manual and hybrid assembly systems continue to represent viable and often preferable solutions, particularly for organisations facing volatile demand, diverse product families, or limited automation budgets. However, designing such systems remains a highly complex task: decision-makers must consider a wide range of layout configurations, workforce strategies, and the variability of human performance. In practice, accessible decision-support tools to guide such choices remain scarce. This dissertation addresses this gap by proposing a simulation-based framework for the design and evaluation of manual assembly systems that explicitly integrates layout alternatives, workforce strategies, and operator heterogeneity. A set of custom-built simulation models developed in MATLAB reproduces stochastic task times, diverse efficiency profiles, and asynchronous flows with parallel stations, capturing the effects of blocking, starving, and worker variability on system performance. Compared to traditional optimisation approaches, the simulation framework provides a more realistic representation of complex dynamics, supports the analysis of non-linear interactions, and allows the exploration of a broad range of scenarios through parametric experiments. The study examines representative layouts widely used in industry—including linear, U-shaped, and parallel configurations—under both fixed-worker and walking-worker strategies. Special attention is devoted to the performance impact of heterogeneous operators, reflecting the reality of modern human-centred systems. The results are presented through comparative analyses and translated into decision-support tools aimed at practitioners. These tools provide practical guidance on selecting the most suitable configuration for specific production contexts, balancing productivity, flexibility, and workforce characteristics. Through the rigorous use of simulation and the consideration of human variability, this research contributes to connect theoretical models and industrial practice. It offers a transparent and adaptable methodology to support managers and system designers in making informed decisions, while also extending the literature by addressing underexplored areas such as asynchronous parallel-station systems with heterogeneous workers. Ultimately, this research shows that human diversity—when properly understood and integrated—can become a key driver of resilience, adaptability, and competitiveness in assembly system design.