A balancing method and genetic algorithm for disassembly line balancing

Disassembly activities take place in various recovery operations including remanufacturing, recycling and disposal. The disassembly line is the best choice for automated disassembly of returned products. It is therefore important that the disassembly line be designed and balanced so that it works as efficiently as possible. The disassembly line balancing problem seeks a sequence which: is feasible, minimizes workstations, and ensures similar idle times, as well as other end-of-life specific concerns. However finding the optimal balance is computationally intensive with exhaustive search quickly becoming prohibitively large even for relatively small products. In this paper the problem is mathematically defined and proven NP-complete. Additionally, a new formula for quantifying the level of balancing is proposed. A first-ever set of a priori instances to be used in the evaluation of any disassembly line balancing solution technique is then developed. Finally, a genetic algorithm is presented for obtaining optimal or near-optimal solutions for disassembly line balancing problems and examples are presented to illustrate implementation of the methodology.     

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.     

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.     

Web server load balancing: A queueing analysis

Over the last few years, the Web-based services, more specifically different types of E-Commerce applications, have become quite popular, resulting in exponential growth in the Web traffic. In many situations, this has led to unacceptable response times and unavailability of services, thereby driving away customers. Many companies are trying to address this problem using multiple Web servers with a front-end load balancer. Load balancing has been found to provide an effective and scalable way of managing the ever-increasing Web traffic. However, there has been little attempt to analyze the performance characteristics of a system that uses a load balancer. This paper presents a queuing model for analyzing load balancing with two Web servers. We first analyze the centralized load balancing model, derive the average response time and the rejection rate, and compare three different routing policies at the load balancer. We then extend our analysis to the distributed load balancing and find the optimal routing policy that minimizes the average response time.     

A genetic algorithm for robotic assembly line balancing

Flexibility and automation in assembly lines can be achieved by the use of robots. The robotic assembly line balancing (RALB) problem is defined for robotic assembly line, where different robots may be assigned to the assembly tasks, and each robot needs different assembly times to perform a given task, because of its capabilities and specialization. The solution to the RALB problem includes an attempt for optimal assignment of robots to line stations and a balanced distribution of work between different stations. It aims at maximizing the production rate of the line. A genetic algorithm (GA) is used to find a solution to this problem. Two different procedures for adapting the GA to the RALB problem, by assigning robots with different capabilities to workstations are introduced: a recursive assignment procedure and a consecutive assignment procedure. The results of the GA are improved by a local optimization (hill climbing) work-piece exchange procedure. Tests conducted on a set of randomly generated problems, show that the Consecutive Assignment procedure achieves, in general, better solution quality (measured by average cycle time). Further tests are conducted to determine the best combination of parameters for the GA procedure. Comparison of the GA algorithm results with a truncated Branch and Bound algorithm for the RALB problem, demonstrates that the GA gives consistently better results.     

A simple load balancing problem with decentralized information

The following load balancing problem is investigated in discrete time: A service system consists of two service stations and two controllers, one in front of each station. The service stations provide the same service with identical service time distributions and identical waiting costs. Customers requiring service arrive at a controller's site and are routed to one of the two stations by the controller. The processes describing the two arrival streams are identical. Each controller has perfect knowledge of the workload in its own station and receives information about the other station's workload with one unit of delay. The controllers' routing strategies that minimize the customers' total flowtime are determined for a certain range of the parameters that describe the arrival process and the service distribution. Specifically, we prove that optimal routing strategies are characterized by thresholds that are either precisely specified or take one of two possible values.     

Periodic load balancing

Multiprocessor load balancing aims to improve performance by moving jobs from highly loaded processors to more lightly loaded processors. Some schemes allow only migration of new jobs upon arrival, while other schemes allow migration of jobs in progress. A difficulty with all these schemes, however, is that they require continuously maintaining detailed state information. In this paper we consider the alternative of periodic load balancing, in which the loads are balanced only at each T time units for some appropriate T. With periodic load balancing, state information is only needed at the balancing times. Moreover, it is often possible to use slightly stale information collected during the interval between balancing times. In this paper we study the performance of periodic load balancing. We consider multiple queues in parallel with unlimited waiting space to which jobs come either in separate independent streams or by assignment (either random or cyclic) from a single stream. Resource sharing is achieved by periodically redistributing the jobs or the work in the system among the queues. The performance of these systems of queues coupled by periodic load balancing depends on the transient behavior of a single queue. We focus on useful approximations obtained by considering a large number of homogeneous queues and a heavy load. When the number of queues is sufficiently large, the number of jobs or quantity of work at each queue immediately after redistribution tends to evolve deterministically, by the law of large numbers. The steady-state (limiting) value of this deterministic sequence is obtained as the solution of a fixed point equation, where the initial value is equal to the expected transient value over the interval between successive redistributions conditional on the initial value. A refined approximation based on the central limit theorem is a normal distribution, where the mean and variance are obtained by solving a pair of fixed-point equations. With higher loads, which is natural to consider when load balancing is performed, a heavy-traffic limit theorem shows that one-dimensional reflected Brownian motion can be used to approximately describe system performance, even with general arrival and service processes. With these approximations, we show how performance depends on the assumed arrival pattern of jobs and the model parameters. We do numerical calculations and conduct simulation experiments to show the accuracy of the approximations. This revised version was published online in June 2006 with corrections to the Cover Date.     

A case study of an adaptive load balancing algorithm

In this paper we present an effective load balancing algorithm for a multi-processor architecture designed for the real time switching of telephone calls. By modifying an algorithm developed for an abstract queueing model, which is of independent interest by itself, we propose a hybrid load balancing algorithm and study its performance in a simulation test-bed. This case study demonstrates how simple abstractions and theoretically intractable but intuitively appealing ideas can be combined to effectively solve a real problem.     

A load balancing system in the many-server heavy-traffic asymptotics

Queueing Systems - We study a load balancing system in the many-server heavy-traffic regime. We consider a system with N servers, where jobs arrive to the system according to a Poisson process and...     

A heuristic solution for fuzzy mixed-model line balancing problem

This paper addresses the mixed-model line balancing problem with fuzzy processing time. A fuzzy binary linear programming model is formulated for the problem. This fuzzy model is then transformed to a mixed zero–one program. Due to the complexity nature in handling fuzzy computation, new approximated fuzzy arithmetic operation is presented. A fuzzy heuristic is developed to solve this problem based on the aggregating fuzzy numbers and combined precedence constraints. The general idea of our approach is to arrange the jobs in a sequence by a varying-section exchange procedure. Then jobs are allocated into workstations based on these aggregated fuzzy times with the considerations of technological constraint and cycle time limit. Promising results are obtained by experiments.     

A station-oriented enumerative algorithm for two-sided assembly line balancing

In this paper, a station-oriented enumerative algorithm for two-sided assembly lines balancing (TALB) is proposed. First, the time transfer function is defined and combined with the precedence relation to compute the earliest and the latest start time of tasks. With the direction and cycle time constraints, a station-oriented procedure based on the start time is designed to assign tasks, starting from the left station to the rightstation of the position. Some unsuitable position assignments would be finally removed by checking the precedence constraints among the assigned tasks. The proposed algorithm is integrated with the Hoffmann heuristic to develop a system for solving TALB problems. The test is performed on the well-known benchmark set of problem instances. Experimental results demonstrate that the proposed procedure is efficient.     

The stochastic U-line balancing problem: A heuristic procedure

Many heuristics have been proposed for the assembly line balancing problem due to its computational complexity and difficulty in identifying an optimal solution. Still, the basic line balancing model fails to consider a number of realistic elements. The implementation of a Just-In-Time manufacturing system generally entails the replacement of traditional straight assembly lines with U-shaped lines. An important issue in the U-line balancing problem is the consideration of task time variability due to human factors or various disruptions. In this paper, we consider the stochastic U-line balancing problem. A hybrid heuristic is presented consisting of an initial feasible solution module and a solution improvement module. To gain insight into its performance, we analyze the heuristic under different scenarios of task time variability. Computational results clearly demonstrate the efficiency and robustness of our algorithm.     

A goal programming approach to simple U-line balancing problem

In this paper, a goal programming model for the simple U-line balancing (ULB) problem is developed. The model is based on the integer programming formulation developed by Urban [Urban, Note: Optimal balancing of U-shaped assembly lines, Management Science 44(5) (1998) 738–741] for the ULB problem and the goal model of Deckro and Rangachari [Deckro, Rangachari, A goal approach to assembly line balancing, Computers and Operations Research 17 (1990) 509–521] developed for the traditional single model assembly line balancing (ALB) problem. The proposed model which is the first multi-criteria decision making approach to the U-line version provides increased flexibility to the decision maker since several conflicting goals can be simultaneously considered.     

Generalized balancing numbers

The positive integer x is a (k, l) -balancing number for y(x ≤ y — 2) if 1^k + 2^k + … + (x — 1)^k = (x + 1)^l + … + (y — 1)^l for fixed positive integers k and l. In this paper, we prove some effective and ineffective finiteness statements for the balancing numbers, using certain Baker-type Diophantine results and Bilu—Tichy theorem, respectively.     

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 hybrid genetic algorithm for sequence-dependent disassembly line balancing problem

For remanufacturing or recycling companies, a reverse supply chain is of prime importance since it facilitates in recovering parts and materials from end-of-life products. In reverse supply chains, selective separation of desired parts and materials from returned products is achieved by means of disassembly which is a process of systematic separation of an assembly into its components, subassemblies or other groupings. Due to its high productivity and suitability for automation, disassembly line is the most efficient layout for product recovery operations. A disassembly line must be balanced to optimize the use of resources (viz., labor, money and time). In this paper, we consider a sequence-dependent disassembly line balancing problem (SDDLBP) with multiple objectives that requires the assignment of disassembly tasks to a set of ordered disassembly workstations while satisfying the disassembly precedence constraints and optimizing the effectiveness of several measures considering sequence dependent time increments. A hybrid algorithm that combines a genetic algorithm with a variable neighborhood search method (VNSGA) is proposed to solve the SDDLBP. The performance of VNSGA was thoroughly investigated using numerous data instances that have been gathered and adapted from the disassembly and the assembly line balancing literature. Using the data instances, the performance of VNSGA was compared with the best known metaheuristic methods reported in the literature. The tests demonstrated the superiority of the proposed method among all the methods considered.     

A special case of transfer lines balancing by graph approach

A balancing problem for paced production lines with workstations in series and blocks of parallel operations at the workstations is considered. Operations of each workstation are partitioned into blocks. All operations of the same block are performed simultaneously by one spindle head. All blocks of the same workstation are also executed simultaneously. The relations of the necessity of executing some operations at the same workstation, the possibility of combining the blocks at the same workstation as well as precedence constraints are given. The operation time of the workstation is the maximal value among operation times of its blocks. The line cycle time is the maximal workstation time. The problem is to choose blocks from a given set and allocate them to workstations in such a way that (i) all the operations are assigned, (ii) the above constraints are satisfied, (iii) a given cycle time is not exceeded, and (iv) the line cost is minimal. A method for solving the problem is based on its transformation to a constrained shortest path problem.