Keywords
How to Cite
Abstract
The system dynamics method is increasingly used in the analysis of modern production systems, but its actual potential in modeling and simulating assembly processes remains a subject of ongoing debate. The article presents an in-depth assessment of this method based on a review of scientific research and a structured SWOT analysis. It is indicated that System Dynamics (SD) enables a holistic approach to assembly processes, integrating, among other things, technical, organizational, and human factors. The authors present SD as a tool capable of capturing nonlinear relationships, feedback loops, and long-term dynamics of production systems, enabling safe testing of development scenarios and investment decisions. At the same time, the barriers to its application are highlighted, including the difficulty of representing discrete events, dependence on data quality, and the complexity of modeling and validation. The study is a critical compendium of knowledge about the possibilities and limitations of the SD method and an inspiration for developing its applications in the analysis of assembly systems.
References
Adane, T. F., Bianchi, M. F., Archenti, A., & Nicolescu, M. (2019). Application of sys-tem dynamics for analysis of perfor-mance of manufacturing systems. Jour-nal of Manufacturing Systems, 53, 212–233. https://doi.org/10.1016/j.jmsy.2019.10.004
Ali, R. M., & Deif, A. M. (2014). Dynamic Lean Assessment for takt Time Imple-mentation. Procedia CIRP, 17, 577–581. https://doi.org/10.1016/j.procir.2014.01.128
Barnuś, K., & Stadnicka, D. (2025). Design for assembly and disassembly with the integration of RRI principles: a system approach to sustainable product devel-opment. Technologia i Automatyzacja Montażu, 130(4), 34–42.
https://doi.org/10.7862/tiam.2025.4.3
Borges, G. D., Reis, A. M., Neto, R. A., De Mattos, D. L., Cardoso, A., Gonçalves, H., Merino, E., Colim, A., Carneiro, P., & Arezes, P. (2021). Decision-Making Framework for Implementing Safer Hu-man-Robot Collaboration Workstations: System Dynamics Modeling. Safety, 7, 75. https://doi.org/10.3390/safety7040075
Catalano, F., Zennaro, I., & Persona, A. (2025). Manned assembly systems design considering layout, workforce strategy, and workers’ heterogeneity: state of the art and future research agenda. The Inter-national Journal of Advanced Manufactur-ing Technology, 139(9–10), 4315–4337. https://doi.org/10.1007/s00170-025-16189-0
Chen, S., Pan, Y., Chen, L., & Wu, D. D. (2020). A System Dynamics Model for Capacity Planning of Component Supply in Complex Product Manufacturing. IEEE Systems Journal, 15(1), 8–16. https://doi.org/10.1109/jsyst.2019.2950627
Cohen, Y., Naseraldin, H., Chaudhuri, A., & Pilati, F. (2019). Assembly systems in Industry 4.0 era: a road map to under-stand Assembly 4.0. The International Journal of Advanced Manufacturing Technology, 105(9), 4037–4054.
https://doi.org/10.1007/s00170-019-04203-1
Daaboul, J., Bernard, A., & Laroche, F. (2010). Extended value network model-ling and simulation for mass customiza-tion implementation. Journal of Intelli-gent Manufacturing, 23(6), 2427–2439. https://doi.org/10.1007/s10845-010-0493-1
De Carlo, F., & Arleo, M. A. (2016). System Dynamics limits and potentialities in the use of production process simulation. Flore Institutional Repository.
https://flore.unifi.it/handle/2158/1091216
De Mattos, D. L., Neto, R. A., Merino, E. A. D., & Forcellini, F. A. (2018). Simulating the influence of physical overload on as-sembly line performance: A case study in an automotive electrical component plant. Applied Ergonomics, 79, 107–121.
https://doi.org/10.1016/j.apergo.2018.08.001
Deif, A. M., & ElMaraghy, H. A. (2010). Modelling and analysis of dynamic ca-pacity complexity in multi-stage produc-tion. Production Planning & Control, 20(8), 737–749. https://doi.org/10.1080/09537280903119072
Gejo-García, J., Reschke, J., Gallego-García, S., & García-García, M. (2022). Devel-opment of a System Dynamics Dimula-tion for Assessing Manufacturing Sys-tems Based on the Digital Twin Concept. Applied Sciences, 12(4), 2095.
https://doi.org/10.3390/app12042095
Größler, A. (2010). An exploratory system dynamics model of strategic capabilities in manufacturing. Journal of Manufactur-ing Technology Management, 21(6), 651–669. https://doi.org/10.1108/17410381011063978
Guenther, R., Liang, J., Exner, R., & Schmitt, R. H. (2022). Towards accurate failure prediction in manual assembly by estab-lishing a System Dynamics model. Pro-cedia CIRP, 112, 495–500.
https://doi.org/10.1016/j.procir.2022.09.090
Gupta, V., Narayanamurthy, G., & Acharya, P. (2018). Can lean lead to green? As-sessment of radial tyre manufacturing processes using system dynamics model-ling. Computers & Operations Research, 89, 284–306. https://doi.org/10.1016/j.cor.2017.03.015
Ionescu, D., Filipescu, A., Simion, G., Mincă, E., Cernega, D., Șolea, R., & Filipescu, A. (2022). Communication and Control of an Assembly, Disassembly and Repair Flexible Manufacturing Technology on a Mechatronics Line Assisted by an Au-tonomous Robotic System. Inventions, 7(2), 43. https://doi.org/10.3390/inventions7020043
Lane, D. C. (2008). The emergence and use of diagramming in system dynamics: a crit-ical account. Systems Research and Be-havioral Science, 25(1), 3–23. https://doi.org/10.1002/sres.826
Liang, J., Guenther, R., Beckschulte, S., Exner, R., Kiesel, R., & Schmitt, R. H. (2021). Quantification of a System Dy-namics Model for Optimized Failure Management in Manual Assembly. In In-stitutional Repository of Leibniz Universi-tät Hannover. https://doi.org/10.15488/11278
Linnéusson, G., & Boldt, S. (2024). Towards Assessing the Economic Sustainability of Reconfigurable Modularization in Semi-Automatic Assembly Systems: A System Dynamics Perspective. Systems, 12(6), 218.
https://doi.org/10.3390/systems12060218
Litwin, P., (2023). Zastosowanie metody dy-namiki systemów w analizie procesów produkcyjnych. Oficyna Wydawnicza Politechniki Rzeszowskiej.
Litwin, P., Gola, A., Wójcik, Ł., & Cioch, M. (2023). Optimization of the Flow of Parts in the Process of Brake Caliper Regenera-tion Using the System Dynamics Meth-od. Processes, 12(1), 16.
https://doi.org/10.3390/pr12010016
Liu, P., Atifeh, M., Khorshidnia, M., & Taheri, S. G. (2023). System dynamics: an approach to modeling supply chain performance measurement. Technological and Economic Development of Economy, 29(4), 1291–1317.
https://doi.org/10.3846/tede.2023.19211
Md Fauadi, M., Muhammad Damanhuri, A., Yahaya, S., Mohamed Noor, A., & Hao, X. (2022). Agent-Based Discrete Event Simulation – System Dynamics Ap-proach to optimize Manufacturing Sys-tem with Maintenance Activi-ties. Journal of Advanced Manufacturing Technology (JAMT), 16(2). https://jamt.utem.edu.my/jamt/article/view/6376
Morecroft, J.D.W., & Sterman, J.D. (1994). Modelling For Learning Organizations. Productivity Press.
Oleghe, O., & Salonitis, K. (2019). The appli-cation of a hybrid simulation modelling framework as a decision-making tool for TPM improvement. Journal of Quality in Maintenance Engineering, 25(3), 476–498. https://doi.org/10.1108/jqme-06-2018-0056
Oumer, A., Atnaw, S. M., Cheng, J. K., & Singh, L. (2016). Modeling Energy Effi-ciency as a Green Logistics Component in Vehicle Assembly Line. IOP Confer-ence Series Materials Science and Engi-neering, 160, 012068.
https://doi.org/10.1088/1757-899x/160/1/012068
Oumer, A. J., Cheng, J. K., & Tahar, R. M. (2015). Evaluating the environmental impact of inbound logistics in automo-tive assembly line: A system dynamics approach. In Proceedings of the 5th IEEE International Conference on System Engi-neering and Technology (pp. 1–5). IEEE. https://doi.org/10.1109/icsengt.2015.7412435
Oyarbide, A., Baines, T. S., Kay, J. M., & Ladbrook, J. (2003). Manufacturing sys-tems modelling using system dynamics: Forming a dedicated modelling tool. Journal of Advanced Manufacturing Sys-tems, 02(01), 71–87.
https://doi.org/10.1142/s0219686703000228
Pasha, N. , Rabieh, M. , Eslamifar, G. & Ra-zavi Hajiagha, S. H. (2023). Analyzing the Manual and Automated Assembly Line Using System Dynamics (SD) Ap-proach. Journal of Systems Thinking in Practice, 2(1), 1–27. https://doi.org/10.22067/jstinp.2023.78113.1017
Qorbani, D., & Groesser, S. (2020). The im-pact of Industry 4.0 technologies on pro-duction and supply chains. ArXiv (Cor-nell University). https://doi.org/10.48550/ARXIV.2004.06983
Stadnicka, D., & Litwin, P. (2019). Value stream mapping and system dynamics in-tegration for manufacturing line model-ling and analysis. International Journal of Production Economics, 208, 400–411. https://doi.org/10.1016/j.ijpe.2018.12.011
Sweetser, A. (1999). A Comparison of System Dynamics (SD) and Discrete Event Simulation (DES). In 17th International Conference of the System Dynamics Socie-ty, 20–23.
Tesfamariam, D., & Lindberg, B. (2005). Ag-gregate analysis of manufacturing sys-tems using system dynamics and ANP. Computers & Industrial Engineering, 49(1), 98–117.
https://doi.org/10.1016/j.cie.2005.05.001
Thramboulidis, K., Vachtsevanou, D. C., & Solanos, A. (2018). Cyber-physical mi-croservices: An IoT-based framework for manufacturing systems. In Proceedings of the IEEE International Conference on Industrial Cyber-Physical Systems. https://doi.org/10.1109/ICPHYS.2018.8387665
Xu, Wang, C., Bi, Z., & Yu, J. (2013). Ob-ject-Oriented Templates for Automated Assembly Planning of Complex Products. IEEE Transactions on Automation Science and Engineering, 11(2), 492–503. https://doi.org/10.1109/tase.2012.2232652
Yang, H., Bukkapatnam, S. T., & Barajas, L. G. (2012). Continuous flow modelling of multistage assembly line system dynam-ics. International Journal of Computer In-tegrated Manufacturing, 26(5), 401–411. https://doi.org/10.1080/0951192x.2012.719085