The performance of unpaced unreliable production lines that are unbalanced in terms of their buffer storage sizes is investigated in this article. Lines are simulated at different levels of line length, total buffer capacity and mean buffer capacity, and for each of these the configuration of buffer allocation is varied. Output data on throughput, idle time and average buffer level are analysed using a range of statistical tools, and relationships between the independent and dependent variables were determined. The best patterns in terms of generating higher throughput rates (or lower idle times) and lower average buffer levels as compared to a balanced line are those where total available buffer capacity is allocated as evenly as possible between workstations and to concentrate more buffer capacity towards the end of the line, respectively.
