An efficient grouping genetic algorithm for U-shaped assembly line balancing problems with maximizing production rate

Şahin, Murat; Kellegöz, Talip

doi:10.1007/s12293-017-0239-0

Cited by 22 publications

(10 citation statements)

References 29 publications

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“…It is a classic problem and there is a significant volume of literature about it. Sahin and Kellegoz (2017) solved an operator assignment problem to minimize the cycle time for U-shaped assembly line balancing problems. Li et al (2017) modeled an operator assignment problem as an integer programming problem to minimize cycle time for U-shaped assembly lines.…”

Section: Operator Assignment Problemsmentioning

confidence: 99%

A study of the operator assignment problem in powder-coating processing using simulation optimization

Yang

Wang

Kuo

2023

RIA

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Purpose The main operations of the powder-coating process are staggered along a closed-loop conveyor. Given the volatile market demands, using a fixed level of staffing may result in significant productivity losses. The present study aims to capture stochastic behavior and optimize operator assignment problems in a practical powder-coating process. By using the proposed methodology, when demand changes, the optimal operator assignment configuration can be provided, ensuring high labor productivity. Design/methodology/approach The powder-coating process is an important industrial application and is often a labor-intensive system. The present study adopts a practical case to optimize its staffing level. Because of its operational complexity, the problem is solved by a proposed simulation-optimization approach. The results are promising, and the proposed methodology is shown to be an effective approach. Findings The proposed methodology was tested for various demand levels. The optimized operator assignment configuration always improves on the performance of other staffing levels. Given the same daily throughput, the optimized operator assignment configuration can improve performance by as much as 19%. In scenarios where there is increased demand, the resulting reduction in overtime work improves performance by between 20.33% and 56.72%. In scenarios where there is reduced demand, the optimized staffing level produces improvements between 3.13% and 50%. Compared with the fixed staffing policy of the case company, the flexible staffing policy of the proposed methodology can maintain high labor productivity across demand variations. The results are consistent with the Shojinka philosophy of the Toyota Production System. Originality/value This study proposes a solution to the operator assignment decision in a labor-intensive manufacturing system – a powder-coating processing system. Powder coating provides a solid powder coating without any solvent. Because of its excellent application performance and environmental protection, it is widely used in the field of metal coating, especially appliances for offices and homes. Most of the existing literature has solved the problem by making unrealistic assumptions. The present study proposes a simulation-optimization method to solve a practical problem in powder-coating processing. The effectiveness of the proposed methodology is illustrated by a practical application. According to the experimental results, five operators can be saved for the same daily throughput. An average of 35 and 19 min of overtimes can be saved when demand increases by 10% and 20% with one less operator; between 2 and 16 operators can be saved when demand falls by 10%–60%.

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Section: Operator Assignment Problemsmentioning

confidence: 99%

A study of the operator assignment problem in powder-coating processing using simulation optimization

Yang

Wang

Kuo

2023

RIA

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“…Li, M. et al (2017) proposed a rule-based heuristic approach, which systematically considered task selection, task assignment and task exchange rules together to minimize the cycle time of the UALBP. Sahin and Kellegoz (2017) designed a grouped algorithm to maximise the production rate of the UALBP. This algorithm merged a genetic algorithm (GA) with a simulated annealing method (SA) to improve performance.…”

Section: Current State Of the Art For The U-shaped Assembly Linementioning

confidence: 99%

Ergonomic risk and cycle time minimization for the U-shaped worker assignment assembly line balancing problem: A multi-objective approach

Zhang

Ruíz

Zhang

2020

Computers & Operations Research

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“…Alavidoost et al (2017) and Alavidoost et al (2015) considered fuzzy task time and proposed an adaptive GA with the one-fifth success rule to solve simple straight line problem and UALBP. Şahin and Kellegöz (2017a) used group GA to study Type II UALBP. According to benchmark examples, they compared the algorithm with simulated annealing algorithm and particle swarm optimization algorithm to verify their algorithm’s effectiveness.…”

Section: Introductionmentioning

confidence: 99%

Balancing of parallel U-shaped assembly lines with a heuristic algorithm based on bidirectional priority values

Jiao

Deng

et al. 2021

Concurrent Engineering

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Aiming at improving assembly line efficiency and flexibility, a balancing method of parallel U-shaped assembly line system is proposed. Based on the improved product priority diagram, the bidirectional priority value formula is obtained. Then, assembly lines are partitioned into z-q partitions and workstations are defined. After that, the mathematical model of the parallel U-shaped assembly line balancing problem is established. A heuristic algorithm based on bidirectional priority values is used to solve explanatory examples and test examples. It can be seen from the results and the effect indicators of the assembly line balancing problem that the heuristic algorithm is suitable for large balancing problems. The proposed method has higher calculation accuracy and shorter calculation time. The balancing effect of the parallel U-shaped assembly line is better than that of single U-shaped assembly line, which verifies the superiority of the parallel U-type assembly line and effectiveness of the proposed method. It provides a theoretical and practical reference for parallel U-type assembly line balancing problem.

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An efficient grouping genetic algorithm for U-shaped assembly line balancing problems with maximizing production rate

Cited by 22 publications

References 29 publications

A study of the operator assignment problem in powder-coating processing using simulation optimization

A study of the operator assignment problem in powder-coating processing using simulation optimization

Ergonomic risk and cycle time minimization for the U-shaped worker assignment assembly line balancing problem: A multi-objective approach

Balancing of parallel U-shaped assembly lines with a heuristic algorithm based on bidirectional priority values

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