System design and flexible workforce capacity management in an electronics manufacturing service provider's environment using simulation

In the current market scenario, manufacturing organizations are facing extreme pressures to maintain quality and expected service levels at an affordable price. Survival has become an art of balancing multiple competing objectives and controlling the operational costs since it governs the organization's profit margins. In organizations having greater dependency on manual operations, labor wages is driving the direct operational costs. To maintain profit margins along with a competitive edge in the market, workforce management tools have become a necessity to strike the required balance in labor force composition.;The objective of this research endeavor is to identify that near optimal workforce size and workforce composition for packaging operations in an Electronics Manufacturing production facility. The study involves designing and developing the production facility from scratch. Simulation is used to study the system characteristics and identify the critical parameters that govern system output. Resource allocation matrix based to simulation analysis is proposed. Finally to incorporate system agility to counter demand variability a simulation model is used to validate flexible workforce proposals.