IMPOV: A Methodology for Validating Production Line Balancing Through Simulation and Multi-Criteria Analysis

Line balancing (LB) in production processes is a crucial part of optimizing workstations, improving efficiency and productivity in the industrial environment. Over the years, various methods and applications, both theoretical and practical, are developed to achieve this goal. However, while there are numerous studies in line balancing optimization, little attention has been paid to its effective validation in real industrial environments. Consequently, it is essential to propose a methodology that integrates both aspects: the theoretical development of solutions and the empirical validation of their effectiveness in practice. This paper presents the case of the final assembly process of an electronic board for a metal detector, based on real data, focusing on the need identified in the literature and proposing a comprehensive methodology to validate the implementation of line balancing. The Integrated Method for Process Optimization and Validation (IMPOV) methodology is proposed, which validates the implementation of line balancing through a Value Stream Mapping (VSM) approach and simulates the process using FlexSim 2024® software. Finally, the optimal solution is validated with the help of the multi-criteria method Multi-Objective Optimization by Ratio Analysis (MOORA). Through the application of this methodology, the final assembly line was optimized, eliminating five operating positions and significantly reducing idle time from 79.16% to 14.06%. As a result, the utilization of process resources increased from 27.84% to 85.95%, which in turn increased production from 5,578 to 9,393 units. This methodology provides professionals in the industrial sector with an effective tool for optimizing assembly processes, ensuring the best alternative for the efficient use of each resource before physically implementing any changes, identifying areas of opportunity and correcting them in advance. This contributes to achieving higher levels of competitiveness and ensuring permanence in the global market.