Simple heuristics for the assembly line worker assignment and balancing problem

We propose simple heuristics for the assembly line worker assignment and balancing problem. This problem typically occurs in assembly lines in sheltered work centers for the disabled. Different from the classical simple assembly line balancing problem, the task execution times vary according to the assigned worker. We develop a constructive heuristic framework based on task and worker priority rules defining the order in which the tasks and workers should be assigned to the workstations. We present a number of such rules and compare their performance across three possible uses: as a stand-alone method, as an initial solution generator for meta-heuristics, and as a decoder for a hybrid genetic algorithm. Our results show that the heuristics are fast, they obtain good results as a stand-alone method and are efficient when used as a initial solution generator or as a solution decoder within more elaborate approaches.Comment: 18 pages, 1 figur

Iterative Beam Search for Simple Assembly Line Balancing with a Fixed Number of Work Stations

The simple assembly line balancing problem (SALBP) concerns the assignment of tasks with pre-defined processing times to work stations that are arranged in a line. Hereby, precedence constraints between the tasks must be respected. The optimization goal of the SALBP-2 version of the problem concerns the minimization of the so-called cycle time, that is, the time in which the tasks of each work station must be completed. In this work we propose to tackle this problem with an iterative search method based on beam search. The proposed algorithm is able to obtain optimal, respectively best-known, solutions in 283 out of 302 test cases. Moreover, for 9 further test cases the algorithm is able to produce new best-known solutions. These numbers indicate that the proposed iterative beam search algorithm is currently a state-of-the-art method for the SALBP-2

Heuristic methods for cost-oriented assembly line balancing: a survey

This paper is concerned with cost-oriented assembly line balancing. This problem occurs especially in the final assembly of automotives, consumer durables or personal computers, where production is still very labour- intensive, and where the wage rates depend on the requirements and qualifications to fulfil the work. First a short problem description is presented. After that a classi"cation of existent and new heuristic methods for solving this problem is given. The heuristic methods presented in this paper are described in detail. A new priority rule called ` best change of idle cost a is proposed. This priority rule di!ers from the existent priority rules because it is the only one which considers that production cost are the result of both, production time and cost rates. Furthermore a new sophisticated method called ` exact solution of sliding problem windows a is presented. The solution process is illustrated by an example, showing how this metaheuristic works together with an exact method.Assembly line balancing; Cost-oriented production planning; Heuristic methods

A mixed-integer programming model for cycle time minimization in assembly line balancing: Using rework stations for performing parallel tasks

[EN] In assembly lines, rework stations are generally used for reprocessing defective items. On the other hand, using rework stations for this purpose only might cause inefficient usage of the resources in this station especially in an assembly line with a low defective rate. In this study, a mixed-integer programming model for cycle time minimization is proposed by considering the use of rework stations for performing parallel tasks. By linearizing the non-linear constraint about parallel tasks using a variate transformation, the model is transformed to a linear-mixed-integer form. In addition to different defective rates, different rework station positions are also considered using the proposed model. The performance of the model is analyzed on several test problems from the related literature.Cavdur, F.; Kaymaz, E. (2020). A mixed-integer programming model for cycle time minimization in assembly line balancing: Using rework stations for performing parallel tasks. 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Research Trends and Outlooks in Assembly Line Balancing Problems

This paper presents the findings from the survey of articles published on the assembly line balancing problems (ALBPs) during 2014-2018. Before proceeding a comprehensive literature review, the ineffectiveness of the previous ALBP classification structures is discussed and a new classification scheme based on the layout configurations of assembly lines is subsequently proposed. The research trend in each layout of assembly lines is highlighted through the graphical presentations. The challenges in the ALBPs are also pinpointed as a technical guideline for future research works

Two extensions for the ALWABP: Parallel stations and collaborative approach

[EN] In this article, we introduce two new variants of the ALWABP that allow parallelization of and collaboration between heterogeneous workers. These new approaches suppose an additional level of complexity in the Line Design and Assignment process, but also higher flexibility; which may be particularly useful in practical situations where the aim is to progressively integrate slow or limited workers in conventional assembly lines. We present linear models and heuristic procedures for these two new problems. Computational results show the efficiency of the proposed approaches and the efficacy of the studied layouts in different situations.This research was supported by CAPES-Brazil and MEC-Spain (coordinated project CAPES-DGU 258-12/PHB-0012-PC) and by FAPESP-Brazil. We also thank the project ‘‘CORSARI MAGIC DPI2010-18243’’ of the Ministerio de Ciencia e Innovación del Gobierno de España within the Program ‘‘Proyectos de Investigación Fundamental No Orientada’’.Araujo, FF.; Costa, AM.; Miralles Insa, CJ. (2012). Two extensions for the ALWABP: Parallel stations and collaborative approach. International Journal of Production Economics. 140(1):483-495. https://doi.org/10.1016/j.ijpe.2012.06.032S483495140

Reducing physical ergonomic risks at assembly lines by line balancing and job rotation: A survey

Factors such as repetitiveness of work, required application of forces, handling of heavy loads, and awkward, static postures expose assembly line workers to risks of musculoskeletal disorders. As a rule, companies perform a post hoc analysis of ergonomic risks and examine ways to modify workplaces with high ergonomic risks. However, it is possible to lower ergonomic risks by taking ergonomics aspects into account right from the planning stage. In this survey, we provide an overview of the existing optimization approaches to assembly line balancing and job rotation scheduling that consider physical ergonomic risks. We summarize major findings to provide helpful insights for practitioners and identify research directions