TCF plants include manual and automated assembly stations, with buffers in between stations to allow for the randomness in cycle times from one job to the next. During the design phase for TCF, the layout is evaluated to determine the efficiency of flow. Parts are usually received just in time and delivered directly to the assembly line. Smooth, efficient flow of parts between dock doors and the line is important. Additionally, during the design phase a line balance is performed to determine the work requirements at each assembly station.
Simulation is used to evaluate the line balance under dynamic conditions.
In a TCF, as in most manual assembly applications, every job's cycle time will be slightly different. Simulation can represent the randomness seen in the real world, which helps determine the interactions between stations on the line. Buffering between stations is evaluated by simulation as well. Buffers provide enough jobs between stations so that assembly line workers are blocked or starved as little as possible. Design phase simulation can also include a downtime analysis of the TCF facility.