A simulation model for optimizing component placement in an assembly process

Abstract This article presents a simulation-based approach to optimizing the placement of components and semi-finished products within an assembly area of a production hall. The developed model focuses on minimizing the total distance traveled by internal transport vehicles – such as AGVs – during the execution of production tasks. A key constraint of the model is the fixed layout of transport routes, which reflects common spatial limitations in real production systems. Therefore, the optimization is limited to the allocation of components in relation to the assembly stations. The simulation model was developed using the FlexSim environment and has a design-oriented character, utilizing hypothetical data. This enables flexible testing of multiple layout scenarios without relying on real-world operational inputs. The proposed approach offers a practical tool for supporting layout planning and internal logistics design in the early phases of manufacturing system development. Additionally, it facilitates comparative analysis of alternative material handling strategies under varying transport capacities and system configurations.