Balancing assembly lines operating with heterogeneous workers under uncertainty in task processing times

This paper proposes a new type of assembly line worker assignment and balancing problem (ALWABP) which considers ergonomic risks. ALWABP occurs when task times vary according to the assigned worker. Although the operation time of a task is assumed to be fixed in classical assembly lines, it depends on the operator who executes the task in ALWABP. In ALWABP literature, the primary and secondary objectives are minimizing cycle time and balancing workload among workstations smoothly, respectively. When smoothing workload, only task times are taken into consideration in the relevant literature. However, degree of difficulty of tasks is also very important. Two workers executing two different stations with the same station time are assumed to be equally loaded according to the traditional perception. In fact, even they have the same station time; their workloads are different because of the different tasks they execute, in real life assembly line configurations. In order to close this gap between the real life and the literature, this study introduces an ALWABP problem with considering ergonomic risk factors (ErgoALWABP). Due to the complex nature of the problem, optimum seeking methods are not capable of solving it. So, the proposed problem is tackled with the multiple-rule based constructive randomized search approach. Also, OCcupational Repetitive Action method is used for making ergonomic risk assessment. Performance of the proposed solution procedure is compared with the relevant literature on benchmark data. Experimental results show that ergonomic environment could be improved when ergonomic risk factors are taken into account.

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

The shortest path problem is considered as one of the essential problems in network optimization with a wide range of real-world applications. Modelling such real-world applications involves various indeterminate phenomena which can be estimated through human beliefs. The uncertainty theory proposed by Liu (Uncertain theory, 2nd edn., Springer, Berlin, 2007) is widely regarded as a legitimate tool to deal with such uncertainty. This paper presents an uncertain multi-objective shortest path problem (UMSPP) for a weighted connected directed graph (WCDG), where every edge weight is associated with two uncertain parameters: cost and time. These parameters are represented as uncertain variables. Here, we have formulated the expected value model and chance-constrained model of the proposed UMSPP, and the corresponding deterministic transformation of these models is also presented. Subsequently, the deterministic models are solved with a classical multi-objective solution method, namely the global criterion method. Furthermore, two multi-objective genetic algorithms (MOGAs): nondominated sorting genetic algorithm II (NSGA-II) and multi-objective cross-generational elitist selection, heterogeneous recombination and cataclysmic mutation (MOCHC), are employed to solve these models. A suitable example is provided to illustrate the proposed model. Finally, the performance of MOGAs is compared for five randomly generated instances of UMSPP.

This paper addresses the problem of profit-oriented disassembly line design and balancing considering partial disassembly, presence of hazardous parts and uncertainty of task processing times. Few papers have studied the stochastic disassembly line balancing problem and existing approaches have focused on heuristic and metaheuristic methods. Most existing work has concentrated on complete disassembly where task times are assumed to be normal random variables and where AND/OR graphs are not considered. The objective of this paper is the design of a serial line that obtains the maximum revenue and then balances the workload under uncertainty. The processing time of a disassembly task is assumed to be a random variable with any known probability distribution. An AND/OR graph is used to model the precedence relationships among tasks. Stochastic programming models and exact-based solution approaches combining the L-shaped algorithm and Monte Carlo sampling techniques are proposed. The relevance and applicability of the proposed models and solution methods are shown by solving efficiently a set of disassembly problem instances from the literature.

Assembly lines can be employed successfully in sheltered work centres to better include persons with disabilities in the labour market as well as to improve production efficiency. The optimal assignment of a heterogeneous workforce is known as the assembly line worker assignment and balancing problem (ALWABP). These assembly lines are characterised not only by a heterogeneous workforce, but also by high levels of absenteeism, which makes it more difficult to obtain stable and efficient line balancing solutions. In this paper, an extension of the ALWABP to minimise the expected cycle time under uncertain worker availability is proposed. We model this problem as a two-stage mixed integer program, and propose local search heuristics for solving it. Computational experiments show that stochastic modelling can help to improve the line’s efficiency and that the proposed heuristics produce good results for instances of practical size.

Minimizing maximum cost for a single machine under uncertainty of processing times

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.

A population-based algorithm for the bi-objective assembly line worker assignment and balancing problem

Assembly line rebalancing is a problem companies are frequently confronted with as continuous changes in product features and volume demand caused by the volatility of modern markets result in re-definition of assembly tasks and line cycle time fluctuations. Consequently, managers are forced to adjust the balancing of their lines in order to adapt to the new conditions while trying to minimise both increases in completion costs and costs related to changes in task assignment. In particular, when modifications are made to line balancing, costs are incurred for operator training, equipment switching and moving, and quality assurance. The stochastic assembly line rebalancing problem is essentially composed of a multi-objective problem in which two joint objectives, total expected completion cost of the new line and similarity between the new and the existing line, must be optimised. Consequently, this paper presents a multiple single-pass heuristic algorithm developed for the purpose of finding the most complete set of dominant solutions representing the Pareto front of the problem. The operative parameters of the heuristic are set as a result of a great deal of experimentation. Moreover, a multi-objective genetic algorithm is developed and then compared with the proposed heuristic in order to demonstrate its effectiveness. Finally, an illustrative case study is presented.

Integrated process planning and scheduling is a significant research focus in recent years, which could improve the performance of manufacturing system. In real manufacturing environment, multi-objectives should be taken into consideration simultaneously during the machining process. Meanwhile, the processing time for each job is often imprecise in many real applications. Therefore, multi-objective integrated process planning and scheduling (IPPS) problem with fuzzy processing time is addressed in this paper. The processing time is described as triangular fuzzy number. A multi-objective genetic algorithm (MOGA) is designed to search for the Pareto solutions of multi-objective IPPS problem with fuzzy processing time. An instance has been designed to test the performance of proposed algorithm. The experiment result shows that the proposed MOGA could obtain satisfactory Pareto solutions for the multi-objective IPPS problem with fuzzy processing time.

Assembly line worker assignment and balancing problem (ALWABP) is an important research topic originated from sheltered work centres for disabled, in which workforce is assumed to be heterogeneous due to their disabilities. Since the employment of disabled workers may sustain higher absenteeism rates due to their health, especially under COVID-19, employing temporary workers to fill labour shortage is a crucial issue. In addition, in practice, the movement of workers between stations on assemble lines can increase the flexibility of worker assignment. In this study, we investigate a new risk-averse ALWABP with uncertain disabled worker availability, limited temporary workers and moving workers. The objective is to minimise the risk-averse weighted sum of the cycle time and the number of employed temporary workers. For the problem, a risk-averse two-stage stochastic programming model is formulated. The first stage assigns specific tasks (called fixed tasks) to stations, while the second stage assigns workers and remaining tasks (called flexible tasks) to stations. A genetic algorithm combining K-means clustering approach and variable neighbourhood search (GAKV) is designed. Experiment results show the superiority of the GAKV in terms of solution quality and computation time compared with sample average approximation (SAA). In addition, managerial insights are drawn.

Advances in robust optimization approaches for scheduling under uncertainty

This research compares SERU manufacturing systems to traditional assembly lines, focusing on the impact of uncertainty in task processing time on production output. The study considers worker skill levels and team identity, using a stochastic mixed integer linear programming approach to model uncertainty and optimize workforce allocation. Discrete event simulation is then integrated to evaluate performance using five key performance indicators (KPIs). Results show that SERU systems outperform traditional lines in terms of throughput when uncertainty is considered. The integrated approach provides more reliable performance data than deterministic optimization alone. The study also highlights the advantages of SERU systems when worker skill levels and team identity are factored in. This research fills a gap in the literature by proposing a stochastic optimization approach that considers uncertainty and worker skill levels, and by integrating stochastic optimization with simulation for comprehensive analysis. This approach provides valuable guidance for production managers in optimizing production systems.

There are many uncertain factors in job shop scheduling problems. However, those uncertainties are critical for the scheduling procedures. The imprecise processing times are modeled as triangular fuzzy numbers (TFNs) and the due dates are modeled as trapezium fuzzy numbers in this paper. A multi-objective genetic algorithm is proposed to solve fuzzy job shop scheduling problems, in which the objective functions are conflicting. Agreement index (AI) is used to show the satisfaction of client which is defined as value of the area of processing time membership function intersection divided by the area of the due date membership function. The multi-objective function is composed of maximize both the minimum agreement and maximize the average agreement index. Two benchmark problems were used to show the effectiveness of the proposed approach. Experimental results demonstrate that the multi-objective genetic algorithm does not get stuck at a local optimum easily, and it can solve job-shop scheduling problems with fuzzy processing time and fuzzy due date effectively.

Although assembly lines are designed to be highly efficient and very cost effective, they have been criticised for their effects on workers. Assembly workers usually perform repetitive tasks and sit or stand for long periods of time, therefore they are at high risk of work-related injuries such as musculoskeletal disorders. In this study, we present a new assembly line balancing problem that incorporates not only task precedence and processing times but also physical workloads in order to reduce work-related injuries. We consider the physical workload of a task as a fuzzy concept and propose a fuzzy linear programming model. The proposed model is applied to an assembly line balancing problem in a textile company and to some of the benchmark problems in order to illustrate the effects of physical workloads.