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

Balancing of parallel U-shaped assembly lines

Copyright © 2015 Elsevier. This is a PDF file of an unedited manuscript that has been accepted for publication in Computers & Operations Research (doi: 10.1016/j.cor.2015.05.014). As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting galley proof before it is published in its final citable form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain. Please cite this article as: Ibrahim Kucukkoc, David Z. Zhang, Balancing of parallel U-shaped assembly Lines, Computers & Operations Research, http://dx.doi.org/10.1016/j.cor.2015.05.014A new hybrid assembly line design, called Parallel U-shaped Assembly Line system, is introduced and characterised along with numerical examples for the first time. Different from existing studies on U-shaped lines, we combine the advantages of two individual line configurations (namely parallel lines and U-shaped lines) and create an opportunity for assigning tasks to multi-line workstations located in between two adjacent U-shaped lines with the aim of maximising resource utilisation. Utilisation of crossover workstations, in which tasks from opposite areas of a same U-shaped line can be performed, is also one of the main advantages of the U-shaped lines. As in traditional U-shaped line configurations, the newly proposed line configuration also supports the utilisation of crossover workstations. An efficient heuristic algorithm is developed to find well-balanced solutions for the proposed line configurations. Test cases derived from existing studies and modified in accordance with the proposed system in this study are solved using the proposed heuristic algorithm. The comparison of results obtained when the lines are balanced independently and when the lines are balanced together (in parallel to each other) clearly indicates that the parallelisation of U-shaped lines helps decrease the need for workforce significantly.Balikesir UniversityTurkish Council of Higher Educatio

Metaheuristic approach to solving U-shaped assembly line balancing problems using a rule-base coded genetic algorithm

Includes bibliographical references.2015 Summer.The need to achieve line balancing for a U-shaped production line to minimize production time and cost is a problem frequently encountered in industry. This research presents an efficient and quick algorithm to solve the U-shape line-balancing problem. Heuristic rules used to solve a straight line-balancing problem (LBP) were modified and adapted so they could be applied in a U-shape line-balancing problem model. By themselves, the heuristic rules, which were adapted from straight-line systems, can produce good solutions for the U-shape LBP, however, there is nothing that guarantees that this will be the case. One way to achieve improved solutions using heuristic rules can be accomplished by using a number of rules simultaneously to break ties during the task assignment process. In addition to the use of heuristic and simultaneous heuristic rules, basic genetic operations were used to further improve the performance of the assignment process and thus obtain better solutions. Two genetic algorithms are introduced in this research: a direct-coded and an indirect-coded model. The newly introduced algorithms were compared with well-known problems from literature and their performance as compared to other heuristic approaches showed that they perform well. The indirect-coded genetic algorithm uses the adapted heuristic rules from the LBP as genes to find the solutions to the problem. In the direct-coded algorithm, each gene represents an operation in the LBP and the position of the gene in the chromosome represents the order in which an operation, or task, will be assigned to a workstation. The indirect-coded genetic algorithm introduces sixteen heuristic rules adapted from the straight LBP for use in a U-shape LBP. Each heuristic rule was represented inside the chromosome as a gene. The rules were implemented in a way that precedence is preserved and at the same time, facilitate the use of genetic operations. Comparing the algorithm’s results with known results from literature, it obtained better solutions in 26% of the cases; it obtained an equivalent solution in 62% of the cases (not better, not worse); and a worse solution the remaining 12%. The direct-coded genetic algorithm introduces a new way to construct an ordered arrangement of the task assignation without violating any precedence. This method consists of creating a diagram that is isomorphic to the original precedence diagram to facilitate the construction of the chromosome. Also, crossover and mutation operations are conducted in a way that precedence relations are not violated. The direct-coded genetic algorithm was tested with the same set of problems as the indirect-coded algorithm. It obtained better solutions than the known solutions from literature in 22% of the cases; 72% of the problems had an equivalent solution; and 6% of the time it generated a solution less successful than the solution from literature. Something that had not been used in other genetic algorithm studies is a response surface methodology to optimize the levels for the parameters that are involved in the response model. The response surface methodology is used to find the best values for the parameters (% of children, % of mutations, number of genes, number of chromosomes) to produce good solutions for problems of different sizes (large, medium, small). This allows for the best solution to be obtained in a minimum amount of time, thus saving computational effort. Even though both algorithms produce good solutions, the direct-coded genetic algorithm option requires less computational effort. Knowing the capabilities of genetic algorithms, they were then tested in two real industry problems to improve assembly-line functions. This resulted in increased efficiency in both production lines

Type-E Parallel Two-Sided Assembly Line Balancing Problem: Mathematical Model and Ant Colony Optimisation based Approach with Optimised Parameters

Copyright © 2015 Elsevier. This is a PDF file of an unedited manuscript that has been accepted for publication in Computers and Industrial Engineering (doi:10.1016/j.cie.2014.12.037). The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.There are many factors which affect the performance of a complex production system. Efficiency of an assembly line is one of the most important of these factors since assembly lines are generally constructed as the last stage of an entire production system. Parallel two-sided assembly line system is a new research domain in academia though these lines have been utilised to produce large sized products such as automobiles, trucks, and buses in industry for many years. Parallel two-sided assembly lines carry practical advantages of both parallel assembly lines and two-sided assembly lines. The main purpose of this paper is to introduce type-E parallel two-sided assembly line balancing problem for the first time in the literature and to propose a new ant colony optimisation based approach for solving the problem. Different from the existing studies on parallel assembly line balancing problems in the literature, this paper aims to minimise two conflicting objectives, namely cycle time and number of workstations at the same time and proposes a mathematical model for the formal description of the problem. To the best of our knowledge, this is the first study which addresses both conflicting objectives on a parallel two-sided assembly line configuration. The developed ant colony optimisation algorithm is illustrated with an example to explain its procedures. An experimental design is also conducted to calibrate the parameters of the proposed algorithm using response surface methodology. Results obtained from the performed computational study indicate that minimising cycle time as well as number of workstations help increase system efficiency. It is also observed that the proposed algorithm finds promising results for the studied cases of type-E parallel two-sided assembly line balancing problem when the results are compared with those obtained from other three well-known heuristics

Time and space multi-manned assembly line balancing problem using genetic algorithm

Purpose: Time and Space assembly line balancing problem (TSALBP) is the problem of balancing the line taking the area required by the task and to store the tools into consideration. This area is important to be considered to minimize unplanned traveling distance by the workers and consequently unplanned time waste. Although TSALBP is a realistic problem that express the real-life situation, and it became more practical to consider multi-manned assembly line to get better space utilization, few literatures addressed the problem of time and space in simple assembly line and only one in multi-manned assembly line. In this paper the problem of balancing bi-objective time and space multi-manned assembly line is proposed Design/methodology/approach: Hybrid genetic algorithm under time and space constraints besides assembly line conventional constraints is used to model this problem. The initial population is generated based on conventional assembly line heuristic added to random generations. The objective of this model is to minimize number of workers and number of stations. Findings: The results showed the effectiveness of the proposed model in solving multi-manned time and space assembly line problem. The proposed method gets better results in solving real-life Nissan problem compared to the literature. It is also found that there is a relationship between the variability of task time, maximum task time and cycle time on the solution of the problem. In some problem features it is more appropriate to solve the problem as simple assembly line than multi-manned assembly line. Originality/value: It is the first article to solve the problem of balancing multi-manned assembly line under time and area constraint using genetic algorithm. A relationship between the problem features and the solution is found according to it, the solution method (one sided or multi-manned) is definedPeer Reviewe

Mathematical model and agent based solution approach for the simultaneous balancing and sequencing of mixed-model parallel two-sided assembly lines

Copyright © 2014 Elsevier. NOTICE: this is the author’s version of a work that was accepted for publication in International Journal of Production Economics. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication. A definitive version was subsequently published in International Journal of Production Economics, DOI: 10.1016/j.ijpe.2014.08.010One of the key factors of a successfully implemented mixed-model line system is considering model sequencing problem as well as the line balancing problem. In the literature, there are many studies, which consider these two tightly interrelated problems individually. However, we integrate the model sequencing problem in the line balancing procedure to obtain a more efficient solution for the problem of Simultaneous Balancing and Sequencing of Mixed-Model Parallel Two-Sided Assembly Lines. A mathematical model is developed to present the problem and a novel agent based ant colony optimisation approach is proposed as the solution method. Different agents interact with each other to find a near optimal solution for the problem. Each ant selects a random behaviour from a predefined list of heuristics and builds a solution using this behaviour as a local search rule along with the pheromone value. Different cycle times are allowed for different two-sided lines located in parallel to each other and this yields a complex problem where different production cycles need to be considered to build a feasible solution. The performance of the proposed approach is tested through a set of test cases. Experimental results indicate that considering model sequencing problem with the line balancing problem together helps minimise line length and total number of required workstations. Also, it is found that the proposed approach outperforms other three heuristics tested

Ant colony optimization for the single model U-type assembly line balancing problem

Cataloged from PDF version of article.An assembly line is a production line in which units move continuously through a sequence of stations. The assembly line balancing problem is defined as the allocation of tasks to an ordered sequence of stations subject to precedence constraints with the objective of optimizing a performance measure. In this paper, we propose ant colony algorithms to solve the single-model U-type assembly line balancing problem. We conduct an extensive experimental study in which the performance of the proposed algorithm is compared against best known algorithms reported in the literature. The results indicate that the proposed algorithms display very competitive performance against them. & 2009 Elsevier B.V. All rights reserved

Integrating ant colony and genetic algorithms in the balancing and scheduling of complex assembly lines

Copyright © 2015 Springer. This is a PDF file of an unedited manuscript that has been accepted for publication in The International Journal of Advanced Manufacturing Technology. The final publication is available at: http://link.springer.com/article/10.1007/s00170-015-7320-y. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.Different from a large number of existing studies in the literature, this paper addresses two important issues in managing production lines, the problems of line balancing and model sequencing, concurrently. A novel hybrid agent-based ant colony optimization–genetic algorithm approach is developed for the solution of mixed model parallel two-sided assembly line balancing and sequencing problem. The existing agent-based ant colony optimization algorithm is enhanced with the integration of a new genetic algorithm-based model sequencing mechanism. The algorithm provides ants the opportunity of selecting a random behavior among ten heuristics commonly used in the line balancing domain. A numerical example is given to illustrate the solution building procedure of the algorithm and the evolution of the chromosomes. The performance of the developed algorithm is also assessed through test problems and analysis of their solutions through a statistical test, namely paired sample t test. In accordance with the test results, it is statistically proven that the integrated genetic algorithm-based model sequencing engine helps agent-based ant colony optimization algorithm robustly find significantly better quality solutions

The Application of Single-Pass Heuristics for U-Lines

U-lines have been adopted in many manufacturing settings as part of JIT implementation. In this paper, we examine the applicability of existing straight-line heuristics for obtaining a balance on a U-line. We modify 13 single-pass heuristics and study the effectiveness of various heuristics under different problem conditions. An extensive computational study is carried out to help identify the best heuristics. In addition, we compare recent U-line procedures with a single-pass heuristic using some literature problems. Based on a single-pass heuristic, we compare the configurations of a straight- and U-line