Impact of Absenteeism on Assembly Line Quality and Throughput

Assembly lines function best when every worker is present. When a worker is absent, management must scramble to quickly find a replacement. Usually, the replacement will not be as proficient as the absent worker. This can reduce quality and throughput. We present two assembly line work-systems models (one for lines with Andon and one for lines without Andon) that show one mechanism whereby absenteeism could impact quality and throughput. We exercise these models to provide insights into absenteeism's impact on quality and throughput. While the paper is written in the concrete terms of automotive assembly, the concepts and results apply to manual assembly lines in general.