A priority rule-based constructive heuristic and an improvement method for balancing assembly lines with parallel multi-manned workstations

An efficient branch and bound algorithm for assembly line balancing problems with parallel multi-manned workstations

The manufacturing industry has evolved in the past decades, due to the competition of the global economy, where the market demands high quality and customized products, and meeting lowest possible costs are paramount. One of the many processes in manufacturing is the assembly line operation, namely the assembly line balancing (ALB) problem. ALB problem is dependent on optimum resource utilization in order to improve production output, reduces costs, and shortens production lead times. In these recent years, various approaches have been proposed to solve the complexity of assembly line balancing operations, which composed of exact, heuristic, and meta-heuristic approaches. However, little work had been done to solve the type E assembly line balancing problem. This paper proposed an approach using artificial immune system (AIS) algorithm, namely as the artificial immune cell (AIC) approach, for solving type E assembly line balancing problem. An initialization mechanism through the bone marrow model and probabilistic clonal selection mechanism had encouraged efficient exploration and exploitation of the solution space. The computational results over 242 instances of 24 datasets had demonstrated the efficiency of the proposed AIC approach by achieving high-quality solutions (up to 85.94% optimum solutions was obtained). Also, the results were statistically justified by comparing with multi-rule multi-objective simulated annealing (MRMOSA), priority-based genetic approach (PriGA), two-phased genetic approach (2P-GA), and assignment genetic approach (MA-GA).  Â

Enumerations and stability analysis of feasible and optimal line balances for simple assembly lines

Worker assignment is a new type of problem in assembly line balancing problems, which typically occurs in sheltered work centers for the disabled. However, only a few contributions consider worker assignment in a two-sided assembly line. This research presents three variants of artificial bee colony algorithm to solve worker assignment and line balancing in two-sided assembly lines. The utilization of meta-heuristics is motivated by the NP-hard nature of the problem and the chosen methods utilize different operators for onlooker phase and scout phase. The proposed algorithms are tested on 156 cases generated from benchmark problems. A comparative study is conducted on the results obtained from the three proposed variants and other well-known metaheuristic algorithms, such as simulated annealing, particle swarm optimization and genetic algorithm. The computational study demonstrates that the proposed variants produce more promising results and are able to solve this new problem effectively in an acceptable computational time.

With the increasing pressure from the market and the surge of “Industry 4.0,” staying competitive and relevant is becoming more and more difficult. The assembly line, which represents a long-term investment of the manufacturing industry, needs to be efficiently utilized. While assembly line balancing (ALB) problem had been studied for decades, oversights on the bottleneck resources could significantly impede its efficiency. In leveraging such information as part of the optimization problem, a contagious artificial immune network (CAIN) approach is proposed to simultaneously address ALB efficiency and bottleneck resources while achieving a truly balanced production line. A computational experiment conducted on benchmark data sets has demonstrated a proof-of-concept, where leveraging knowledge-intensive optimization approach had successfully produced high-quality solutions up to 100% improvement with statistically significant justification. Such findings may play an essential determinant in the manufacturing industry, whether being relevant or left out in the era of increasingly being information-driven.

In real-world assembly lines, that the size of the product is large (e.g., automotive industry), usually there are multi-manned workstations where a group of workers simultaneously perform different operations on the same individual product. This paper presents a mixed integer programming model to solve the balancing problem of the multi-manned assembly lines optimally. This model minimizes the total number of workers on the line as the first objective and the number of opened multi-manned workstations as the second one. Since this problem is well known as NP (nondeterministic polynomial-time)-hard, a heuristic approach based on the ant colony optimization approach is developed to solve the medium- and large-size scales of this problem. In the proposed algorithm, each ant tries to allocate given tasks to multi-manned workstations in order to build a balancing solution for the assembly line balancing problems by considering the precedence relations, multi-manned assembly line configuration, task times, and cycle time constraints. Through computational experiments, the performance of the proposed ACO is compared with some existing heuristic on various problem instances. The experimental results validate the effectiveness and efficiency of the proposed algorithm.

Constraint programming for solving various assembly line balancing problems

In this paper, type II robotic mixed-model two-sided assembly line balancing (RMTALB-II) problem is considered. In recent years, robots have been widely used in assembly systems as called robotic assembly lines where a set of tasks have to be assigned to stations and each station needs to select one of the different robots to process the assigned tasks. Two-sided assembly lines are especially used to produce large-sized high-volume products, such as automobiles, trucks, and buses. In this type of production line, both left side and right side of the line are used in parallel. However, little attention has been paid to solve RMTALB problems. Moreover, according to our best knowledge, there is no published work in the literature on RMTALB. This paper presents a new mixed-integer programming model for RMTALB-II to minimize the cycle time for a given number of mated stations. Since RMTALB problems are in NP-hard class of combinatorial optimization problems, a simulated annealing (SA) algorithm as metaheuristic method is proposed to solve the problem. Some problems are solved by SA and performance of the SA is evaluated by comparing their results with the optimal solution. The computational results show that SA is more efficient.

The paper describes difficulties in estimation of the quality of assembly line balancing problem (ALBP). The mentioned problem is NP-hard and even optimal solutions can contain idle times. The objective of optimization ALBP is to minimize the number of workstations on an assembly line for a given cycle time (TYPE 1) or to minimize the value of cycle time for a given number of workstations (TYPE 2). Since more than 50 years many exact and heuristic methods were introduced to solve the problem. As a result we get sequence of assigned tasks to the workstations of the assembly line. The additional problem is to choose appropriate solutions because of existing idle times. Some quality performances help to estimate the final results. In this paper efficiency line, smoothness index and time of the line are discussed. Author underlines the problem of differences between cycle time and maximum station load. Numerical examples are presented and conclusion are given.

This paper presents an approach, based on ant techniques, to effectively address the assembly line balancing problem with the complicating factors of parallel workstations, stochastic task durations, and mixed-models. A methodology was inspired by the behavior of social insects in an attempt to distribute tasks among workers so that strategic performance measures are optimized. This methodology is used to address several assembly line balancing problems from the literature. The assembly line layouts obtained from these solutions are used for simulated production runs so that output performance measures (such as cycle time performance) are obtained. Output performance measures resulting from this approach are compared to output performance measures obtained from several other heuristics, such as simulated annealing. A comparison shows that the ant approach is competitive with the other heuristic methods in terms of these performance measures.

Assembly sequence planning (ASP) and assembly line balancing (ALB) problems are two essential problems in the assembly optimization. This paper proposes an ant colony algorithm for integrating assembly sequence planning and assembly line balancing, to deal with the two problems on parallel, and resolve the possible conflict between two optimization goals. The assembly sequence planning problem and the assembly line balancing problem are discussed, the process of the proposed ant colony algorithm is investigated. The results can provide a set of solutions for decision department in assembly planning.

Worker assignment is a relatively new problem in assembly lines that typically is encountered in situations in which the workforce is heterogeneous. The optimal assignment of a heterogeneous workforce is known as the assembly line worker assignment and balancing problem (ALWABP). This problem is different from the well-known simple assembly line balancing problem concerning the task execution times, and it varies according to the assigned worker. Minimal work has been reported in worker assignment in two-sided assembly lines. This research studies worker assignment and line balancing in two-sided assembly lines with an objective of minimizing the cycle time (TALWABP). A mixed-integer programming model is developed, and CPLEX solver is used to solve the small-size problems. An improved migrating birds optimization algorithm is employed to deal with the large-size problems due to the NP-hard nature of the problem. The proposed algorithm utilizes a restart mechanism to avoid being trapped in the local optima. The solutions obtained using the proposed algorithms are compared with well-known metaheuristic algorithms such as artificial bee colony and simulated annealing. Comparative study and statistical analysis indicate that the proposed algorithm can achieve the optimal solutions for small-size problems, and it shows superior performance over benchmark algorithms for large-size problems.

An assembly system consists of work stations where specific tasks are carried in such a way that last station gives the complete product. An assembly line balancing Problem (ALBP) involves optimally assigning tasks among workstations with respect to some performance objective. ALBP problems are of NP hard nature and in literature; many efforts are there to solve the problem efficiently through heuristics. This paper proposes a heuristic algorithm for solving type 2 ALBP for single objective optimization. The proposed algorithm assigns tasks to a fixed no of stations with objective of minimizing cycle time. In literature, type 2 ALBP is mostly solved through Type 1 problem. However, this paper proposes a direct approach to Type 2 ALBP. The effectiveness is tested through application on Gunther problem of 35 tasks with forty five precedence constraints. The task assignment for six stations is computed and it shows competitive performance. The number of fixed stations is varied and corresponding cycle times are computed. The algorithm is also tested on a real industrial problem of 24 tasks. The experimental testing indicates tendency of the proposed algorithm to give effective optimal results.

Balancing U-shaped assembly lines with resource dependent task times: A Simulated Annealing approach

PurposeAssembly lines are widely employed in manufacturing processes to produce final products in a flow efficiently. The simple assembly line balancing problem is a basic version of the general problem and has still attracted the attention of researchers. The type-I simple assembly line balancing problems (SALBP-I) aim to minimise the number of workstations on an assembly line by keeping the cycle time constant.Design/methodology/approachThis paper focuses on solving multi-objective SALBP-I problems by utilising an artificial bee colony based-hyper heuristic (ABC-HH) algorithm. The algorithm optimises the efficiency and idleness percentage of the assembly line and concurrently minimises the number of workstations. The proposed ABC-HH algorithm is improved by adding new modifications to each phase of the artificial bee colony framework. Parameter control and calibration are also achieved using the irace method. The proposed model has undergone testing on benchmark problems, and the results obtained have been compared with state-of-the-art algorithms.FindingsThe experimental results of the computational study on the benchmark dataset unequivocally establish the superior performance of the ABC-HH algorithm across 61 problem instances, outperforming the state-of-the-art approach.Originality/valueThis research proposes the ABC-HH algorithm with local search to solve the SALBP-I problems more efficiently.