Simulation-Based Optimization of an Electronics Assembly Line | Case Study

The client was developing a production line for an innovative electronic assembly incorporating piezoelectric switching components.

The initial line concept assumed the involvement of seven operators distributed across the production process. At the same time, the location and number of four key production machines had already been defined and could not be changed.

The remaining areas of the line therefore had to be arranged around these fixed constraints while ensuring sufficient material flow and throughput.

The main challenge was to determine:

• how many operators were actually required,
• how the machines and workstations should be arranged,
• where and how large the process buffer should be,
• whether the proposed layout would provide sufficient capacity for the four fixed machines,
• and whether the complete concept would meet the required production assumptions.

Key questions

• Does the proposed line layout meet the required throughput?
• Are seven operators necessary to operate the process?
• How should the workstations be arranged to improve operator efficiency?
• What buffer capacity is required to stabilize material flow?
• Where should the buffer be located within the line?
• Can the remaining process stations continuously supply the four fixed production machines?

Simulation objectives

• Validate the proposed production line concept
• Determine the required number of operators
• Optimize workstation and machine placement
• Define the required buffer size and location
• Increase throughput across the remaining process stations
• Ensure sufficient material flow to the four fixed machines
• Visualize the line concept and recommended changes for the client

Nextomation developed a detailed production line simulation and digital modelling of the proposed electronics assembly process. The model represented the planned machine arrangement, operator allocation, material flow and interaction between individual process areas, allowing the production concept to be evaluated before the physical layout was finalized.

Several layout and staffing scenarios were analyzed. The simulation examined operator workloads, movement between workstations, utilization of the available production area and the capacity of the surrounding process stations. This data-driven approach helped determine whether the original concept could meet the required throughput while continuously supplying the four production machines whose location and quantity had already been fixed.

The analysis also identified the need for an intermediate process buffer. Its required capacity and optimal location were defined within the simulation, resulting in a conveyor-based buffer positioned centrally within the production area. Based on the simulation results, the layout and staffing concept could be modified before implementation, reducing the required workforce from seven operators to three while maintaining the necessary material flow.

This type of optimization is an important element of custom automated assembly lines, where decisions regarding equipment layout, staffing, material flow and buffer capacity have a direct impact on future throughput, operating costs and production stability.

For electronics manufacturing automation, simulation provides a way to validate production concepts before committing to a final layout and equipment configuration. The same methodology can support demanding applications such as electronic module assembly and testing, where multiple process and quality-control operations must be coordinated within a stable production flow, as well as display assembly and optical alignment, where precise process sequencing and equipment interaction are critical to production performance.

The project clearly demonstrates why simulation matters in automation design: assumptions regarding workforce, layout and process capacity can be tested against measurable production requirements before costly physical changes are made. In this case, simulation transformed an initial concept based on seven operators into a leaner configuration requiring only three.

By combining simulation with production engineering expertise, the final concept provided a more efficient use of operators, equipment and available floor space while maintaining the required throughput and creating a stronger basis for future implementation.

1. Initial layout verification

The original production concept was recreated in the simulation environment to verify whether the planned arrangement could meet the required throughput.

2. Operator workload analysis

The simulation evaluated how production tasks could be distributed between operators and whether the originally assumed staffing level was justified.

3. Layout optimization

Machine and workstation placement was adjusted to improve process flow and reduce inefficient operator movement.

4. Buffer sizing and positioning

The simulation was used to determine the required intermediate buffer and define its optimal position within the production line.

5. Throughput validation

The optimized process was assessed against the capacity requirements of the four fixed production machines, which were the main reference point for the line design.

6. Concept visualization

The simulation provided the client with a clear visualization of the proposed layout and demonstrated how the recommended changes would affect line operation.

The simulation confirmed that the original concept could be significantly optimized.

Key outcomes included:

• reduction of the required workforce from seven operators to three,
• optimization of the production line layout,
• more efficient placement of machines and workstations,
• definition of the required intermediate buffer,
• selection of an appropriate buffer location within the line,
• increased process throughput through improved equipment arrangement,
• confirmation that the surrounding stations could provide sufficient capacity for the four fixed production machines,
• identification and correction of concept issues before physical implementation.

The project demonstrated how simulation can be used to challenge initial production assumptions and replace them with data-based decisions.

Reducing the required workforce from seven operators to three created the potential for substantial long-term operating cost savings. At the same time, the optimized layout improved the use of available production space and supported higher process efficiency.

The main business benefits included:

• significantly lower staffing requirements,
• reduced operating costs,
• improved production efficiency,
• more effective utilization of operators and equipment,
• a properly sized buffer instead of assumption-based capacity planning,
• reduced risk of implementing an inefficient line layout,
• greater confidence in the production concept before implementation,
• clearer communication of the proposed solution through process visualization.

By using simulation during the concept phase, the client was able to verify and optimize the production line before final implementation.

The analysis showed that the process did not require the seven operators originally assumed. An optimized layout, supported by a correctly sized intermediate buffer, enabled the line to operate with only three operators while maintaining the required material flow to four key production machines.

The project confirmed that simulation can deliver value far beyond visualization. It can support workforce planning, layout design, buffer sizing and throughput validation – helping manufacturers create leaner, more efficient and lower-risk production concepts.