An Optimization Model for Balancing Assembly Lines With Stochastic Task Times and Zoning Constraints

Fathi, Masood; Nourmohammadi, Amir; Ng, Amos H. C.; Syberfeldt, Anna

doi:10.1109/access.2019.2903738

Cited by 20 publications

(8 citation statements)

References 55 publications

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“…It is also assumed that the demand for tasks is known in advance in terms of the number of bins. The demand for each task in bins is generated using uniform distribution U (1,10). Assuming that the capacity of supermarkets is limited, the maximum capacity of each supermarket was chosen as equal to 150 bins.…”

Section: Computational Resultsmentioning

confidence: 99%

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Production Sustainability via Supermarket Location Optimization in Assembly Lines

et al. 2020

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Manufacturers worldwide are nowadays in pursuit of sustainability. In the Industry 4.0 era, it is a common practice to implement decentralized logistics areas, known as supermarkets, to achieve production sustainability via Just-in-Time material delivery at assembly lines. In this environment, manufacturers are commonly struggling with the Supermarket Location Problem (SLP), striving to efficiently decide on the number and location of supermarkets to minimize the logistics cost. To address this prevalent issue, this paper proposed a Simulated Annealing (SA) algorithm for minimizing the supermarket cost, via optimally locating supermarkets in assembly lines. The efficiency of the SA algorithm was tested by solving a set of test problems. In doing so, a holistic performance index, namely the total cost of supermarkets, was developed that included both shipment cost and the installation cost across the assembly line. The effect of workload balancing on the supermarket cost was also investigated in this study. For this purpose, the SLP was solved both before and after balancing the workload. The results of the comparison revealed that workload balancing could significantly reduce the total supermarket cost and contribute to the overall production and economic sustainability. It was also observed that the optimization of material shipment cost across the assembly line is the most influencing factor in reducing the total supermarket cost.

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Section: Computational Resultsmentioning

confidence: 99%

“…The task of workload distribution at assembly lines is known as the assembly line balancing problem (ALBP) [9]. The ALBP concerns the proper allocation of work tasks to a set of stations so that all the stations have an equal amount of work while considering and satisfying all the operational and technological requirements [10].…”

Section: Introductionmentioning

confidence: 99%

Production Sustainability via Supermarket Location Optimization in Assembly Lines

et al. 2020

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“…Line balancing may be defined as the decision process of assigning tasks to workstations considering one or more optimization criteria, such as number of worstaions and line efficiency [2], [3]. Line balancing is a common problem in practice and can be classified base on the products models being produced (single-model or mix-model), the nature of task times (deterministic or stochastic) and the type of the production flow (straight-line or U-shaped line), between others [4].…”

Section: Introductionmentioning

confidence: 99%

Combining Line Balancing Methods and Discrete Event Simulation: A Case Study from a Metalworking Company

Mirzaei

Nejad²,

Fernandes

2021

Int J Ind Eng Manag

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In this study, we consider a real-life Line Balancing Problem (LBP) at a metalworking company. Based on the concerns of the company's managers, the number of workstations is considered as the main performance criteria for line balancing, while line efficiency and smoothness are considered as the second and the third performance criteria. Two alternative line configurations, i.e., the straight line and the U-shaped line, are considered in the study as a company request. The Grouping Evolution Strategy (GES) algorithm, as one of the novel and powerful method in the literature, is used at a first step, assuming deterministic task times. At a second step, discrete event simulation is used to analyse the impact of stochastic' times on the dynamic behaviour of the two line configurations in terms of throughput time and throughput rate. Results of this study are expected to contribute to both research and practice in the context of line balancing.

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“…GALBPs have more restrictions or factors such as parallel stations, stochastic task times and zoning constraint (Fathi et al , 2019).…”

Section: Introductionmentioning

confidence: 99%

“…The two groups are (1) the simple assembly line balancing problem (SALBP) where a single model of a product is produced, task times are deterministic and the assembly line is straight and (2) the general assembly line balancing problem (GALBP) which covers all problems that do not fall within SALBP. GALBPs have more restrictions or factors such as parallel stations, stochastic task times and zoning constraint (Fathi et al, 2019).…”

Section: Introductionmentioning

confidence: 99%

An improved genetic algorithm with variable neighborhood search to solve the assembly line balancing problem

Fathi

Nourmohammadi

et al. 2019

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Purpose This study aims to propose an efficient optimization algorithm to solve the assembly line balancing problem (ALBP). The ALBP arises in high-volume, lean production systems when decision-makers aim to design an efficient assembly line while satisfying a set of constraints. Design/methodology/approach An improved genetic algorithm (IGA) is proposed in this study to deal with ALBP to optimize the number of stations and the workload smoothness. Findings To evaluate the performance of the IGA, it is used to solve a set of well-known benchmark problems and a real-life problem faced by an automobile manufacturer. The solutions obtained are compared against two existing algorithms in the literature and the basic genetic algorithm. The comparisons show the high efficiency and effectiveness of the IGA in dealing with ALBPs. Originality/value The proposed IGA benefits from a novel generation transfer mechanism that improves the diversification capability of the algorithm by allowing population transfer between different generations. In addition, an effective variable neighborhood search is used in the IGA to enhance its local search capability.

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An Optimization Model for Balancing Assembly Lines With Stochastic Task Times and Zoning Constraints

Cited by 20 publications

References 55 publications

Production Sustainability via Supermarket Location Optimization in Assembly Lines

Production Sustainability via Supermarket Location Optimization in Assembly Lines

Combining Line Balancing Methods and Discrete Event Simulation: A Case Study from a Metalworking Company

An improved genetic algorithm with variable neighborhood search to solve the assembly line balancing problem

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