Assembly line balancing: What happened in the last fifteen years?

Boysen, Nils; Schulze, Philipp; Schöll, Armin

doi:10.1016/j.ejor.2021.11.043

Cited by 106 publications

(47 citation statements)

References 272 publications

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“…Some studies revised the production line architectures by mixing and integrating two different lines and improved production efficiency, reducing production costs (Zhao et al, 2022). A review study for assembling line balance problems advised using decision support software and experienced planners to reduce planning time and effort (Boysen et al, 2022).…”

Section: Literature Surveymentioning

confidence: 99%

Bi̇r Teksti̇l Şi̇rketi̇ İçi̇n Üreti̇m Hatti Atama Problemi̇

ABDELSALAM>¹,

MOHAMMOUD>²,

EDER>³

et al. 2023

Mühendislik Bilimleri Ve Tasarım Dergisi

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In this study, the production process of Karaman Textiles, for which production planning is done manually, was observed and analyzed. This study aims to minimize the unused machine capacity and idle time of the existing system by developing a mixed integer programming (MIP) model, developing scenarios, and obtaining the results with GAMS software. In addition, the results of the scenarios are compared and evaluated to reach the optimal result that meets and maximizes the efficiency of the production process. The company's usual production planning is done manually and determined according to annual demand. The study aims to minimize the machine working times and that complete planning of the production in the most optimal way. In this study, the company's production time and machine usage times were optimized, and under normal conditions, 15,000 fabric pants were produced for 8 hours a day, 5 days a week, and 4 weeks a month. The scenario analysis aimed to produce by adding 4,000 pieces of velvet pants in addition to 15,000 fabric pants in the first scenario. The second scenario aims to minimize the production time of 15,000 fabric pants by limiting the working times of the machines owned by the company.

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Section: Literature Surveymentioning

confidence: 99%

Bi̇r Teksti̇l Şi̇rketi̇ İçi̇n Üreti̇m Hatti Atama Problemi̇

ABDELSALAM>¹,

MOHAMMOUD>²,

EDER>³

et al. 2023

Mühendislik Bilimleri Ve Tasarım Dergisi

View full text Add to dashboard Cite

show abstract

“…They have been effectively used to solve complex problems with multiple constraints and they have been proven to be capable of generating optimum solutions faster than other optimisation algorithms [27]. Work focusing on GA solving ALBPs have been covered by Tasan [28] and Aytug [29], and solutions with other methods have been summarised by Becker [30], Scholl [31], Boysen [32,33,34], Battaïa [24], Saif [11] and Sivasankaran [35]. Although the subject matter around the application of GAs to line balancing is well covered in each case, the common weakness to date is been the required constraining of the problem to effect a solution and the lack of methods to solve problems considering only the precedence constraints.…”

Section: Theoretical Backgroundmentioning

confidence: 99%

A New Multi-Objective Genetic Algorithm for Assembly Line Balancing

Butterfield

Murphy

2022

Journal of Computing and Information Science in Engineering

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Predictive methods in production planning need to be more intelligent and self-adapting in order to reduce or negate the need for human decision making and / or intervention and deliver on their potential as a key element of Industry 4.0 operations in the manufacturing enterprise. Ultimately, this will facilitate closed loop data flows and ‘lights out’ approaches to the virtual planning and validation of manufacturing systems as well as the creation and function of digital twins for the ongoing operation of the system as the product lifecycle evolves. The aim of this work is to enable a step towards a self-adapting digital toolset for manufacturing planning focusing on minimally constrained assembly line balancing. A bespoke Genetic Algorithm (GENALSAS) has been developed and demonstrated which focuses on examining the Simple Assembly Line Balancing Problem (SALBP). The approach includes the simultaneous definition of the optimum number of workstations, the optimum cycle time and the assignment of tasks to workstations. The GA has been shown to consistently deliver detailed production plans for SALBP problem forms with minimum inputs (neither the number of workstations nor the system cycle time is assumed/fixed as in previous work in the field). The work simultaneously attains better performing solutions compared with previous studies both in terms of time to converge and the quality of the solution.

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“…The design and operation of production lines have originated many complex combinatorial problems in academic research. The most popular one is the assembly line balancing problem (ALBP), which is broadly discussed in the literature (Boysen et al , 2021) under several classifications. The most basic version of the problem, the simple assembly line balancing problem (SALBP), was formally defined by Baybars (1986) with several simplification hypotheses.…”

Section: Introductionmentioning

confidence: 99%

Mixed-integer linear programming models for the type-II resource-constrained assembly line balancing problem

Michels

Costa

2022

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Purpose Resource-constrained assembly lines are widely found in industries that manufacture complex products. In such lines, tasks may require specific resources to be processed. Therefore, decisions on which tasks and resources will be assigned to each station must be made. When the number of available stations is fixed, the problem’s main goal becomes the minimisation of cycle time (type-II version). This paper aims to explore this variant of the problem that lacks investigation in the literature. Design/methodology/approach In this paper, the authors propose mixed-integer linear programming (MILP) models to minimise cycle time in resource-constrained assembly lines, given a limited number of stations and resources. Dedicated and alternative resource types for tasks are considered in different scenarios. Findings Besides, past modelling decisions and assumptions are questioned. The authors discuss how they were leading to suboptimal solutions and offer a rectification. Practical implications The proposed models and data set fulfil more practical concerns by taking into account characteristics found in real-world assembly lines. Originality/value The proposed MILP models are applied to an existing data set, results are compared against a constraint programming model, and new optimal solutions are obtained. Moreover, a data set extension is proposed due to the simplicity of the current one and instances up to 70 tasks are optimally solved.

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Assembly line balancing: What happened in the last fifteen years?

Cited by 106 publications

References 272 publications

Bi̇r Teksti̇l Şi̇rketi̇ İçi̇n Üreti̇m Hatti Atama Problemi̇

Bi̇r Teksti̇l Şi̇rketi̇ İçi̇n Üreti̇m Hatti Atama Problemi̇

A New Multi-Objective Genetic Algorithm for Assembly Line Balancing

Mixed-integer linear programming models for the type-II resource-constrained assembly line balancing problem

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