Manned assembly systems design considering layout, workforce strategy, and workers’ heterogeneity: state of the art and future research agenda

The transition from mass production to mass customisation is accelerating, requiring assembly systems to rapidly adapt their production methods while minimising costs. This shift demands continuous adjustment to a dynamic environment and is further complicated by high workforce turnover and increasing diversity in worker characteristics and capabilities. In this context, the design or re-design of assembly systems becomes critical to align resources effectively and achieve maximum flexibility. Potential solutions include reconfiguring the layout or modifying workforce strategies. This literature review investigates existing decision support systems that assist managers in making informed choices, particularly when dealing with heterogeneous workforces. The analysis highlights a gap in the literature: few studies provide comparative models with practical implications, and most focus on limited alternatives concerning either layout or workforce strategy. Finally, the paper outlines future research directions to address these limitations.