This paper presents an innovative approach for best allocation of crews of workers onproduction processes by combining flow-chart based simulation tool with a powerful genetic optimizationprocedure. The proposed approach determines the least costly and most productive crew allocation on aset of production processes. IDEF0 diagrams were developed to provide generic and functional diagramsfor each process. Discrete Event Simulation Methodology is used to develop the precast-componentmanufacturing simulation model. A proposed GA model is developed to be integrated with the developedsimulation model. This type of integration will add more intelligence to the simulation model for a bettersearch. GA operators were developed to suit this type of problems. A precast concrete manufacturingsystem producing sleepers was chosen as a test bed for the proposed SIM_Crew allocation system.SIM_Crew system is easy to use and can be utilised for large scale manufacturing systems. Based onthis research, computer simulation and genetic algorithms can be an effective combination and offer agreat potential for improving productivity and saving production time and cost. The results showed thatadopting different combinations of possible crews of workers had a substantial impact on reducing thetotal labour cost, process idle time and in maximising the utilisation of skilled workers.
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