An evaluation of constructive heuristic methods for solving the alternative subgraphs assembly line balancing problem

This paper evaluates a set of constructive heuristic methods developed to solve the novel Alternative Subgraphs Assembly Line Balancing Problem (ASALBP), which considers variants for different parts of a production or manufacturing process. Each variant is represented by a precedence subgraph that defines the tasks to be performed and their processing times. The proposed methods use priority rules and random choice to select the assembly subgraphs and to assign the tasks to the stations in order to minimize the number of required workstations. The methods are evaluated by a computational experiment based on medium- and large-scale benchmark problems. This work is supported by the Spanish MCyT project DPI2004-03472, co-financed by FEDER, and by a Venezuelan Grant by the University of Los Andes.     

Enhanced multi-Hoffmann heuristic for efficiently solving real-world assembly line balancing problems in automotive industry

In production systems of automobile manufacturers, multi-variant products are assembled on paced final assembly lines. The assignment of operations to workplaces and workers deter mines the productivity of the manufacturing process. In research, various exact and heuristic solution procedures have been developed for different versions of the so-called assembly line balancing problem.     

An enumeration procedure for the assembly line balancing problem based on branching by non-decreasing idle time

In this article, we present a new exact algorithm for solving the simple assembly line balancing problem given a determined cycle time (SALBP-1). The algorithm is a station-oriented bidirectional branch-and-bound procedure based on a new enumeration strategy that explores the feasible solutions tree in a non-decreasing idle time order. The procedure uses several well-known lower bounds, dominance rules and a new logical test based on the assimilation of the feasibility problem for a given cycle time and number of stations (SALBP-F) to a maximum-flow problem.     

A versatile algorithm for assembly line balancing

This paper discusses a two stage graph-algorithm, which was designed to solve line balancing problems including practice relevant constraints (GALBP), such as parallel work stations and tasks, cost synergies, processing alternatives, zoning restrictions, stochastic processing times or U-shaped assembly lines. Unlike former procedures, the presented approach can be easily modified to incorporate all of the named extensions. It is not only possible to select and solve single classes of constraints, but rather any combination of them with just slight modifications.     

A classification of assembly line balancing problems

Assembly lines are special flow-line production systems which are of great importance in the industrial production of high quantity standardized commodities. Recently, assembly lines even gained importance in low volume production of customized products (mass-customization). Due to high capital requirements when installing or redesigning a line, its configuration planning is of great relevance for practitioners. Accordingly, this attracted attention of many researchers, who tried to support real-world configuration planning by suited optimization models (assembly line balancing problems). In spite of the enormous academic effort in assembly line balancing, there remains a considerable gap between requirements of real configuration problems and the status of research. To ease communication between researchers and practitioners, we provide a classification scheme of assembly line balancing. This is a valuable step in identifying remaining research challenges which might contribute to closing the gap.     

Binary fuzzy goal programming approach to single model straight and U-shaped assembly line balancing

Assembly line balancing generally requires a set of acceptable solutions to the several conflicting objectives. In this study, a binary fuzzy goal programming approach is applied to assembly line balancing. Models for balancing straight and U-shaped assembly lines with fuzzy goals (the number of workstations and cycle time goals) are proposed. The binary fuzzy goal programming models are solved using the methodology introduced by Chang [Chang, C.T., 2007. Binary fuzzy goal programming. European Journal of Operational Research 180 (1), 29–37]. An illustrative example is presented to demonstrate the validity of the proposed models and to compare the performance of straight and U-shaped line configurations.     

A comparison of heuristic algorithms for cost-oriented assembly line balancing

Two new heuristic algorithms for solving cost-oriented assembly line balancing problems -the Wage-Rate-Method (WR) and the Wage-Rate-Smoothing-Method (WRS) — are presented and compared with two known heuristics — the Positional-Weight-Method (PW) and the Positional-Weight-Wage-Rate-Difference-Method (PWWD) with respect to their solution qualities. Firstly, the heuristics are outlined and their computational effort is stated. Then, a theoretical worst-case bound for the solution quality is given and the results of an extensive performance study are reported. In the study the heuristics were investigated with respect to their solution quality by solving randomly generated line balancing problems and problems from literature. It can be concluded that PWWD and WRS are generally superior to PW and WR.Parts of this research have been supported by the Stiftung Industrieforschung.     

A chance-constrained approach to stochastic line balancing problem

In this paper, chance-constrained 0–1 integer programming models for the stochastic traditional and U-type line balancing (ULB) problem are developed. These models are solved for several test problems that are well known in the literature and the computational results are given. In addition, a goal programming approach is presented in order to increase the system reliability, which is arising from the stochastic case.     

Incorporating ergonomic risks into assembly line balancing

In manufacturing, control of ergonomic risks at manual workplaces is a necessity commanded by legislation, care for health of workers and economic considerations. Methods for estimating ergonomic risks of workplaces are integrated into production routines at most firms that use the assembly-type of production. Assembly line re-balancing, i.e., re-assignment of tasks to workers, is an effective and, in case that no additional workstations are required, inexpensive method to reduce ergonomic risks. In our article, we show that even though most ergonomic risk estimation methods involve nonlinear functions, they can be integrated into assembly line balancing techniques at low additional computational cost. Our computational experiments indicate that re-balancing often leads to a substantial mitigation of ergonomic risks.     

Heuristics and lower bounds for the simple assembly line balancing problem type 1: Overview,computational tests and improvements

Assigning tasks to work stations is an essential problem which needs to be addressed in an assembly line design. The most basic model is called simple assembly line balancing problem type 1 (SALBP-1). We provide a survey on 12 heuristics and 9 lower bounds for this model and test them on a traditional and a lately-published benchmark dataset. The present paper focuses on algorithms published before 2011.     

Bi-criteria assembly line balancing by considering flexible operation times

This paper addresses a novel approach to deal with Flexible task Time Assembly Line Balancing Problem (FTALBP). In this regard, machines are considered in which operation time of each task can be between lower and upper bounds. These machines can compress the processing time of tasks, but this action may lead to higher cost due to cumulative wear, erosion, fatigue and so on. This cost is described in terms of task time via a linear function. Hence, a bi-criteria nonlinear integer programming model is developed which comprises two inconsistent objective functions: minimizing the cycle time and minimizing the machine total costs. In order to sustain these objectives concurrently, this paper applies the LP-metric method to make a combined dimensionless objective. Moreover, a genetic algorithm (GA) is presented to solve this NP-hard problem and design of experiments (DOE) method is hired to tune various parameters of our proposed algorithm. The computational results demonstrate the effectiveness of implemented procedures.     

A branch-and-bound algorithm to minimize the line length of a two-sided assembly line

A new branch-and-bound algorithm is presented to solve the two-sided assembly line balancing problem of type 1 (TALB-1). First, a pair of two directly facing station is defined as a position, and then the two-sided assembly line (TAL) is relaxed to a one-sided assembly line (OAL). Some new lower bound on positions are computed, and dominance rules and reduction rules for the one-sided assembly line balancing problem of type 1 (OALB-1) are extended and incorporated into a station-oriented assignment procedure for the TALB-1 problem. Finally, the tests are carried out on a well-known benchmark set of problem instances, and experimental results demonstrate that the proposed procedure is efficient.     

Assembly line balancing as generalized bin packing

Bin packing heuristics are generalized and adapted to solve the assembly line balancing problem. Worst-case analysis is provided. The results are compared to those for a resource constrained scheduling problem considered by Garey, Graham, Johnson and Yao.     

Rules-based heuristic approach for the U-shaped assembly line balancing problem

The type-2 U-shaped assembly line balancing problem is important for many just-in-time manufactures, but an efficient algorithm is not available at present. Thus, in this study, a novel heuristic approach based on multiple rules and an integer programming model is proposed to address this problem. In the proposed approach, three rules are systematically grouped together, i.e., task selection, task assignment, and task exchange rules. The sufficient conditions for implementing the exchange rules are proposed and proved. Thirteen small or medium scale benchmark issues comprising 63 instances were solved, where the computational results demonstrate the efficiency and effectiveness of the proposed method compared with integer programming. The computational results obtained for 18 examples comprising 121 instances demonstrate that the task exchange rules significantly improve the computational accuracy compared with the traditional heuristic. Finally, 30 new standard instances produced by a systematic data generation process were also solved effectively by the proposed approach. The proposed heuristic approach with multiple rules can provide a theoretical basis for other local search algorithms, especially for addressing issues such as the U-Shaped assembly line balancing problem.     

An application of the branch,bound, and remember algorithm to a new simple assembly line balancing dataset

The simple assembly line balancing problem (SALBP) is a well-studied NP-complete problem for which a new problem database of generated instances was published in 2013. This paper describes the application of a branch, bound, and remember (BB&R) algorithm using the cyclic best-first search strategy to this new database to produce provably exact solutions for 86% of the unsolved problems in this database. A new backtracking rule to save memory is employed to allow the BB&R algorithm to solve many of the largest problems in the database.     

Simple and U-type assembly line balancing problems with a learning effect

In this paper, we introduced learning effect into assembly line balancing problems. In many realistic settings, the produced worker(s) (or machine(s)) develops continuously by repeated the same or similar activities. Therefore, the production time of product shortens if it is processed later. We show that polynomial solutions can be obtained for both simple assembly line balancing problem (SALBP) and U-type line balancing problem (ULBP) with learning effect.     

An linear programming based lower bound for the simple assembly line balancing problem

The simple assembly line balancing problem is a classical integer programming problem in operations research. A set of tasks, each one being an indivisible amount of work requiring a number of time units, must be assigned to workstations without exceeding the cycle time. We present a new lower bound, namely the LP relaxation of an integer programming formulation based on Dantzig–Wolfe decomposition. We propose a column generation algorithm to solve the formulation. Therefore, we develop a branch-and-bound algorithm to exactly solve the pricing problem. We assess the quality of the lower bound by comparing it with other lower bounds and the best-known solution of the various instances from the literature. Computational results show that the lower bound is equal to the best-known objective function value for the majority of the instances. Moreover, the new LP based lower bound is able to prove optimality for an open problem.     

Systematic data generation and test design for solution algorithms on the example of SALBPGen for assembly line balancing

Recently, the importance of correctly designed computational experiments for testing algorithms has been a subject of extended discussions. Whenever real-world data is lacking, generated data sets provide a substantive methodological tool for experiments. Focused research questions need to base on specialized, randomized and sufficiently large data sets, which are sampled from the population of interest. We integrate the generation of data sets into the process of scientific testing.     

A dynamic programming heuristic for the P-median problem

A new heuristic algorithm is proposed for the P-median problem. The heuristic restricts the size of the state space of a dynamic programming algorithm. The approach may be viewed as an extension of the myopic or greedy adding algorithm for the P-median model. The approach allows planners to identify a large number of solutions all of which perform well with respect to the P-median objective of minimizing the demand weighted average distance between customer locations and the nearest of the P selected facilities. In addition, the results indicate regions in which it is desirable to locate facilities. Computational results from three test problems are discussed.     

A hybrid heuristic for a multi-objective real-life car sequencing problem with painting and assembly line constraints

We address a multi-objective version of the car sequencing problem, which consists in sequencing a given set of cars to be produced in a single day, minimizing the number of violations of assembly constraints and the number of paint color changes in the production line. We propose a set of heuristics for approximately solving this problem, based on the paradigms of the VNS and ILS metaheuristics, to which further intensification and diversification strategies have been added. Computational results on real-life test instances are reported. The work presented in this paper obtained the second prize in the ROADEF challenge 2005 sponsored by Renault.