Balancing of assembly lines with collaborative robots

Motivated by recent developments to deploy collaborative robots in industrial production systems, we investigate the assembly line balancing problem with collaborative robots. The problem is characterized by the possibility that human and robots can simultaneously execute tasks at the same workpiece either in parallel or in collaboration. For this novel problem type, we present a mixed-integer programming formulation for balancing and scheduling of assembly lines with collaborative robots. The model decides on both the assignment of collaborative robots to stations and the distribution of workload to workers and robotic partners, aiming to minimize the cycle time. Given the high problem complexity, a hybrid genetic algorithm is presented as a solution procedure. Based on extensive computational experiments, the algorithm reveals promising results in both computational time and solution quality. Moreover, the results indicate that substantial productivity gains can be utilized by deploying collaborative robots in manual assembly lines. This holds especially true for a high average number of robots and tasks to be assigned to every station as well as a high portion of tasks that can be executed by the robot and in collaboration.

PurposeCycle time fluctuations in assembly lines are one of the important reasons of re‐balancing. As a result of re‐balancing of assembly lines, it will be necessary to change task sequences or equipment locations. The purpose of this paper is to find the task sequence which enables assembly line balancing (ALB) with minimum number of stations (NS) for different cycle times such that tasks and equipment or fixture locations remain unchanged.Design/methodology/approachIn this paper a heuristic which consist of two stages is proposed to find a common task sequence for different cycle times in assembly lines.FindingsIt is shown that optimal NS for different cycle times can be achieved with a fixed task sequence.Research limitations/implicationsThe approach is limited to a single model case. Model variety together with cycle time variety can be investigated in further studies.Practical implicationsAssembly lines which require less time and cost for re‐balancing can be easily designed by the proposed approach.Originality/valueALB problem is handled with a new viewpoint. Also, it is observed that the proposed approach serves as a bridge between assembly line design and balancing. In this regard, it is thought to have an important place in the ALB literature.

In this chapter, a system to support the design of assembly and production lines used in the make-to-order production phase is presented. The relevance of the system is supported by the fact that current market dynamics often leads to frequent modifications in the allocation of manufacturing resources, and, as a result, decisions related to manufacturing systems design that used to belong to the strategic level are now taken at the tactical level, and thus require new tools to support them.The decision support system addresses two different categories of problems: (i) assembly line balancing and (ii) production line balancing. Due to the high complexity of these problems, it uses heuristic methods based on evolutionary computation approaches to tackle them. The system aggregates several modules to address the different problems, a database to handle both input and output data and an interface that enables a user-friendly interaction with the decision maker.

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.

In real world manufacturing systems there are many combinatorial optimization problems (COP) imposing on more complex issues, such as complex structure, nonlinear constraints, and multiple objectives to be handled simultaneously. Manufacturing scheduling is one of the important and complex COP models, where it can have a major impact on the productivity of a production process. Moreover, the COP models make the problem intractable to the traditional optimization techniques because most of scheduling problems fall into the class of NP-hard combinatorial problems. In order to develop effective and efficient solution algorithms that are in a sense good, i.e., whose computational time is small as within 3 min, or at least reasonable for NP-hard combinatorial problems met in practice, we have to consider: quality of solution, computational time and effectiveness of the nondominated solutions for multiobjective optimization problem (MOP). When solving any NP-hard problem, a genetic algorithm (GA) based on principles from evolution theory is most powerful metaheuristics. In this paper, we concern with the design of hybrid genetic algorithms (HGA) and multiobjective HGA (Mo-HGA) to solve manufacturing scheduling problems. Firstly we introduce typical models in manufacturing scheduling systems such as parallel machines scheduling (PMS), flexible job-shop scheduling problem (FJSP) and assembly line balancing (ALB) problem. Secondly to solve NP-hard COP models, we introduce design scheme of HGA combined with fuzzy logic controller (FLC) and multiobjective HGA (Mo-HGA) with several fitness assignment mechanisms. For demonstrating computational experiments by HGA and Mo-HGA, the effectiveness of the HGA for the HDD (hard disc device) and Mo-HGA for TFT-LCD (thin-film transistor-liquid crystal display) module assembly problems as a practical manufacturing model, respectively is demonstrated in the concatenated paper Part II.

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

The advantages of assembly line balancing provide in knowledge is well known and many researchers actively discussing and doing their research in this field. There are many ways to solve the assembly line balancing problem, one of the techniques that frequently used in assembly line balancing is a simulation approach. In this paper, the power converter assembly line which has 27 major tasks and 19 workstations is studied. The line balancing problem is solved by using two heuristics methods and then, by using simulation, the results from both methods are compared and the best method is chosen.

Firstly, aimed at the existing problem of reconfigurable assembly line (RAL) balancing, the characteristics of RAL are analyzed and the special requirements of balancing are studied. Secondly, the mathematical model is proposed based on two factors, which are integrated including the cycle time and the assembly line efficiency. Then a new hybrid genetic algorithm is developed for finding optimal solution of the problems. Finally, example verification is carried out, and which indicates the validity of the proposed algorithm.

Printed Circuit Boards (PCBs) are widely used in most electronic devices. Typically, a PCB design has a set of components that needs to be assembled. In a broad sense, this assembly task involves placing PCB components at designated location on a PCB board; fixing PCB components; and testing the PCB after assembly operation to ensure that it is in proper working order. The stringent requirements of having a higher component density on PCBs, a shorter assembly time, and a more reliable product prompt manufacturers to automate the process of PCB assembly. Frequently, a few placement machines may work together to form an assembly line. Thus, the application of more than one machine for component placement on a PCB presents a line-balancing problem, which is basically concerned with balancing the workload of all the machines in an assembly line. This paper describes the application of a new artificial intelligence technique known as the immune algorithm to PCB component placement as well as the line balancing of PCB assembly line. It also includes an overview of PCB assembly and an outline of the assembly line balancing problem. Two case studies are used to validate the IA engine developed in this work. The details of IA, the IA engine and the case studies are presented.

Assembly line balancing has been a focus of interest in Industrial Engineering for the last few years. Assembly line balancing is the problem of assigning tasks to workstations by optimizing a performance measure while satisfying precedence relations between tasks and cycle time restrictions. Line balancing is an important feature in ensuring that a production line is efficient and producing at its optimum. The process of Line balancing attempts to equalize the work load on each workstation of the production line. Mixed model assembly lines are increasing in many industries to achieve the higher production rate. This study deals with mixed-model assembly line balancing and uses Yamazumi chart to break down the work element in to the value added & Non-value added part to reduce the waste & increase the productivity.

Line balancing is to distribute the task over the each workstation so that idle time of labor of machine can be minimized. Line balancing aims at grouping the resources or labor in an efficient and best pattern in order to obtain an optimum or proper balance of the resources and flows of the production or assembly processes. Assembly Line Balancing (ALB) is the term commonly used to refer to the decision process of assigning tasks to workstations in a sequential way to the production system. The task of elementary operations required to build raw material into a finished product.
 Line Balancing is a classic Operations Research optimization technique which has significant industrial importance in a lean system. The concept of mass production essentially involves the Line Balancing in assembly of identical or interchangeable parts or components into the final product in various stages at different workstations. With the improvement in knowledge, the refinement in the application of the line balancing procedure is also a must. Task allocation of each worker was achieved by assembly line balancing to increase an assembly efficiency and productivity. In this paper, we discuss and analysis a vehicle manufacturing unit and suggest the options to increase the productivity through an assembly line balancing with the help of Pro Balance.

This study suggests a mathematical modelling approach to sub-assembly detection and assembly line balancing problems. The sub-assembly detection problem involves two issues as follows: 1 determine which components of products are assembled in sub-assembly area; 2 determine which components of the products are assembled directly in the line. In assembly line balancing problem tasks are assigned to the workstations. The main motivation of this study is to determine the best compromised assembly line structure by solving the sub-assembly detection and the line balancing problems jointly. A multi-objective mathematical model is developed to formulate the above mentioned problems in which two conflicting costs of sub-assembly generation and assembly line labour cost are involved. Since the applications in real life are imprecise, fuzzy goal programming is adapted to the developed model to determining the vague goal. Then the model is implemented in a real life automotive manufacturers assembly line balancing.

The most important factor affecting efficiency and ergonomic risk levels in an assembly line design is the problem of assigning certain tasks to certain stations, namely the assembly line balancing problem. In the literature, assembly line balancing problem has often been studied, but studies that consider ergonomic risks are deficient. Recently, it has been one of the issues that have started to attract great attention with the realization of health problems caused by assembly lines. To this end, in this study, a bi‐objective mathematical model is developed that considers balancing assembly line station time and ergonomic risk levels, simultaneously. It is aimed to minimize both station time and the total deviations of ergonomic risk scores for the stations. Weighted sum and conic scalarization methods are applied to solve the bi‐objective model. To analyze the outcomes of the developed model, an application is proposed and tested on a real industrial case, at a home appliance assembly line. The deployment of the OMAX method is a contribution to the literature since it shows an analysis tool which evaluates the results of assembly line balancing. This method evaluates the performance of the stations based on different criteria such as station time and ergonomic risk. The number of high‐risk stations is obtained as 13 in the single‐objective model aiming to minimize the station time, while it is found to be nine in the bi‐objective model solved with CSM, without an increase in the total number of stations.

Purpose The purpose of this paper is to find the most efficient assembly line balancing solution across many heuristic line balancing methods, in assistance with a developed computer program. Design/methodology/approach In this paper, assembly line balancing problem was analyzed using t-shirt and knitted pants data. A computer program using MATLAB software for the solution of assembly line balancing problems has been developed. In this study, following heuristic assembly line balancing methods were applied: Hoffman method; position weight method; COMSOAL method; and Kilbridge and Wester method. A MATLAB program has been developed by taking into account of theoretical solution of all these methods. Later the program is developed further by analyzing solutions made manually and is made to verify the developed program. Findings Pre-studies which were conducted in order to decide which programming language would be the best choice for line balancing methods’ application came out with the result that MATLAB, from between C, C++, C# and Java, would be the best software choice. The main reason for this choice is that MATLAB is a powerful matrix operation software with a powerful user interface designing tool and has the tools to make development program to be used universally in every computer. Originality/value When the researches were investigated, it is clearly seen that, this study is the first research on using computer program for solving assembly line balancing problem.

Assembly line balancing is a hard problem concerned with the assignment of individual work elements or tasks to workstations so as to minimize the assembly cost as much as possible. Decisions associated with line balancing have a direct influence on the costs of production. Basic heuristic algorithms have been widely used to solve the assembly line balancing problem (ALBP). However, to solve hard, large-scale ALBPs, efficient decision tools are essential. Therefore, developing efficient algorithms that can yield optimal or near-optimal solutions is of utmost importance. In this chapter, a hybrid grouping genetic algorithm is developed to address complex problems. The algorithm incorporates basic heuristics, unique genetic operators, and other techniques to enhance the optimization search process. Comparative computational results based on established test problems are presented. The results show that the hybrid grouping genetic algorithm is more efficient and effective than competitive algorithms. The algorithm can be used to assist decision makers in assembly line balancing decisions, with minimal computational requirements.