Production Systems Configurations Considering Human–Machine Task Allocation

This study takes human–machine task allocation as its entry point and systematically examines production-line configuration and combination decisions in multi-product, small-batch manufacturing settings. By considering the trade-offs in cost and flexibility among three production-line types—fully automated intelligent lines, flexible production lines, and manual production lines—the study develops a cost-comparison framework to investigate how firms should choose optimal configuration strategies under different market demand environments to achieve total cost minimization. The results show that production batch size is a key factor determining strategy selection. When the batch size is small, a two-type configuration (combining automated lines and manual lines) achieves cost advantages. When the batch size falls within a medium range, a three-type configuration (integrating automated lines, flexible production lines, and manual lines) exhibits distinct advantages. When the batch size is large, a configuration dominated by flexible production lines yields the lowest cost. Furthermore, when the improvement investment cost is sufficiently low, the investment can significantly reduce production cost and lower the critical boundary for making small-batch production economically feasible, thereby enhancing the practicality of small-batch flexible manufacturing. The study provides a decision-making approach for production-line configuration selection based on production batch-size characteristics.