Manufacturing facilities are expected to maintain a high level of production and at the same time, employ strict safety standards to ensure the safe evacuation of the people in the event of emergencies (fire is considered in this paper). These two goals are often conflicting. This paper presents a methodology to evaluate evacuation safety versus productivity concurrently for various, widely known manufacturing layouts. While the safety performance indicators such as evacuation times are inferred from the crowd (agent based) simulation, the productivity performance indicators (e.g. throughput) are analyzed using the discrete event simulation. To this end, this research focuses on creating innovative techniques for developing accurate crowd simulations, where BDI (Belief-Desire-Intention) agent framework is employed to build each person's individual actions and the interactions between them. The data model and rule based action algorithms for each agent are reverse-engineered from the human-in-the-loop experiments in the immersive virtual reality environments. Finally, experiments are conducted using the constructed simulations to compare safety and productivity for different layouts. To demonstrate the proposed methodology, an automotive power-train (engine and transmission) manufacturing plant was used. Initial results look quite promising.
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