The present study investigates the impact of highly variable characteristics on assembly line balance, with a focus on mass customization in modern manufacturing. The challenges of balancing assembly lines have intensified due to the increasing demand for customization, which has led to greater efficiency, productivity, product quality, and customer satisfaction. To address this issue, the study aims to identify the critical factors that significantly affect assembly line balance. Typical assembly lines are designed for the production of a single product or a narrow range of similar items in high volumes. Therefore, this research employs 3D matrix representation and graphical interpretation with the MATLAB tool to identify the highly variable parameters and their interactions that impact assembly line balance. The results of this analysis demonstrate that modifying the pilot parameters of the assembly line has a significant impact on line balance, necessitating dynamic balancing. The study applies this methodology primarily to the automotive industry, specifically to the wire harness manufacturing line.