Effective Hybrid Teaching-learning-based Optimization Algorithm for Balancing Two-sided Assembly Lines with Multiple Constraints

Due to the NP-hardness of the two-sided assembly line balancing （TALB） problem, multiple constraints existing in real applications are less studied, especially when one task is involved with several constraints. In this paper, an effective hybrid algorithm is proposed to address the TALB problem with multiple constraints （TALB-MC）. Considering the discrete attribute of TALB-MC and the continuous attribute of the standard teaching-learning-based optimization （TLBO） algorithm, the random-keys method is hired in task permutation representation, for the purpose of bridging the gap between them. Subsequently, a special mechanism for handling multiple constraints is developed. In the mechanism, the directions constraint of each task is ensured by the direction check and adjustment. The zoning constraints and the synchronism constraints are satisfied by teasing out the hidden correlations among constraints. The positional constraint is allowed to be violated to some extent in decoding and punished in cost fimction. Finally, with the TLBO seeking for the global optimum, the variable neighborhood search （VNS） is further hybridized to extend the local search space. The experimental results show that the proposed hybrid algorithm outperforms the late acceptance hill-climbing algorithm （LAHC） for TALB-MC in most cases, especially for large-size problems with multiple constraints, and demonstrates well balance between the exploration and the exploitation. This research proposes an effective and efficient algorithm for solving TALB-MC problem by hybridizing the TLBO and VNS.

A Heuristic Method for Two-sided Assembly Line Balancing Problem

A two-sided assembly line is typically found in plants producing large-sized products. Its advantages over a one-sided line and the difficulties faced in two-sided line balancing problems were discussed. A mathematical model for two-ALB problem was suggested. A modification of the “ranked positional weight” method, namely two-ALB RPW for two-ALB problems was developed. Experiments were carried out to verify the performance of the proposed method and the results show that it is effective in solving two-sided assembly line balancing problems.

Genetic Algorithm for Concurrent Balancing of Mixed-Model Assembly Lines with Original Task Times of Models

The growing global competition compels manufacturing organizations to engage themselves in all productivity improvement activities. In this direction, the consideration of mixed-model assembly line balancing problem and implementing in industries plays a major role in improving organizational productivity. In this paper, the mixed model assembly line balancing problem with deterministic task times is considered. The authors made an attempt to develop a genetic algorithm for realistic design of the mixed-model assembly line balancing problem. The design is made using the originnal task times of the models, which is a realistic approach. Then, it is compared with the generally perceived design of the mixed-model assembly line balancing problem.

An efficient migrating birds optimization algorithm with idle time reduction for Type-I multi-manned assembly line balancing problem

Multi-manned assembly line,which is broadly utilized to assemble high volume products such as automobiles and trucks,allows a group of workers to assemble different tasks simultaneously in a multi-manned workstation.This additional characteristic of parallel operators increases the complexity of the traditional NP-hard assembly line balancing problem.Hence,this paper formulates the Type-I multi-manned assembly line balancing problem to minimize the total number of workstations and operators,and develops an efficient migrating birds optimization algorithm embedded into an idle time reduction method.In this algorithm,a new decoding mechanism is proposed which reduces the sequence-dependent idle time by some task assignment rules;three effective neighborhoods are developed to make refinement of existing solutions in the bird improvement phases;and temperature acceptance and competitive mechanism are employed to avoid being trapped in the local optimum.Comparison experiments suggest that the new decoding and improvements are effective and the proposed algorithm outperforms the compared algorithms.

Assembly Line Balancing Based on Double Chromosome Genetic Algorithm

Aiming at assembly line balancing problem,a double chromosome genetic algorithm(DCGA)is proposed to avoid trapping in local optimum,which is a disadvantage of standard genetic algorithm(SGA).In this algorithm,there are two chromosomes of each individual,and the better one,regarded as dominant chromosome,determines the fitness.Dominant chromosome keeps excellent gene segments to speed up the convergence,and recessive chromosome maintains population diversity to get better global search ability to avoid local optimal solution.When the amounts of chromosomes are equal,the population size of DCGA is half that of SGA,which significantly reduces evolutionary time.Finally,the effectiveness is verified by experiments.

A scenario relaxation algorithm for finite scenario based robust assembly line balancing

A balancing problem for a mixed model assembly line with uncertain task processmg Ume anO daily model mixed changes is considered, and the objective is to minimize the work variances between stations in the line. For the balancing problem for the scenario-based robust assembly line with a finitely large number of potential scenarios, the direct solution methodology considering all potential scenarios is quite time-consuming. A scenario relaxation algorithm that embeds genetic al- gorithm is developed. This new algorithm guarantees termination at an optimal robust solution with relatively short running time, and makes it possible to solve robust problems with large quantities of potential scenarios. Extensive computational results are reported to show the efficiency and effectiveness of the proposed algorithm.

CONCURRENT PRODUCT PORTFOLIO PLANNING AND MIXED PRODUCT ASSEMBLY LINE BALANCING

Reconfigurable products and manufacturing systems have enabled manufacturers to provide ＂cost effective＂ variety to the market. In spite of these new technologies, the expense of manufacturing makes it infeasible to supply all the possible variants to the market for some industries. Therefore, the determination of the right number of product variantsto offer in the product portfolios becomes an important consideration. The product portfolio planning problem had been independently well studied from marketing and engineering perspectives. However, advantages can be gained from using a concurrent marketing and engineering approach. Concurrent product development strategies specifically for reconfigurable products and manufacturing systems can allow manufacturers to select best product portfolios from marketing, product design and manufacturing perspectives. A methodology for the concurrent design of a product portfolio and assembly system is presented. The objective of the concurrent product portfolio planning and assembly system design problem is to obtain the product variants that will make up the product portfolio such that oversupply of optional modules is minimized and the assembly line efficiency is maximized. Explicit design of the assembly system is obtained during the solution of the problem. It is assumed that the demand for optional modules and the assembly times for these modules are known a priori. A genetic algorithm is used in the solution of the problem. The basic premise of this methodology is that the selected product portfolio has a significant impact on the solution of the assembly line balancing problem. An example is used to validate this hypothesis. The example is then further developed to demonstrate how the methodology can be used to obtain the optimal product portfolio. This approach is intended for use by manufacturers during the early design stages of product family design.

Heuristics for Mixed Model Assembly Line Balancing Problem with Sequencing

The growing global competition compels organizations to use many productivity improvement techniques. In this direction, assembly line balancing helps an organization to design its assembly line such that its balancing efficiency is maximized. If the organization assembles more than one model in the same line, then the objective is to maximize the average balancing efficiency of the models of the mixed model assembly line balancing problem. Maximization of average balancing efficiency of the models along with minimization of makespan of sequencing models forms a multi-objective function. This is a realistic objective function which combines the balancing efficiency and makespan. This assembly line balancing problem with multi-objective comes under combinatorial category. Hence, development of meta-heuristic is inevitable. In this paper, an attempt has been made to develop three genetic algorithms for the mixed model assembly line balancing problem such that the average balancing efficiency of the model is maximized and the makespan of sequencing the models is minimized. Finally, these three algorithms and another algorithm in literature modified to solve the mixed-model assembly line balancing problem are compared in terms of the stated multi-objective function using a randomly generated set of problems through a complete factorial experiment.

A Modified Multi-Agent System for Simple Assembly Line Balancing

In this paper, a modified multi-agent system for assembly line balancing is proposed. Each worker in the assembly line is regarded as an agent, and two neighboring agents exchange information about the allocated tasks. To balance the workload, an agent with a smaller workload sends a request message to his/her neighboring agent, who has a larger workload, to exchange tasks between them. Without any centralized control mechanism, each agent behaves to achieve their goal, which is to balance the workload. A tabu list and cooling control are also incorporated. However, the effectiveness of the previous system is limited, and the system depends on problems to be solved. As such, a modified system is proposed. In the proposed system, the cycle time is used when considering the proposal of exchange of allocated tasks instead of the task time allocated to the neighboring workers. Also, in the proposed system, the length of tabu list is determined dynamically based on the current number of possible exchanges, and the best cycle time in the search with cooling at medium speed is recorded for the second search that is finished when the current cycle time reaches the recorded cycle time. The effectiveness of the modified system is investigated by solving problems for various conditions. The results show that the proposed system is effective regardless of the problems that are encountered.

Optimization of assembly line balancing using genetic algorithm

In a manufacturing industry, mixed model assembly line(MMAL) is preferred in order to meet the variety in product demand. MMAL balancing helps in assembling products with similar characteristics in a random fashion. The objective of this work aims in reducing the number of workstations, work load index between stations and within each station. As manual contribution of workers in final assembly line is more, ergonomics is taken as an additional objective function. Ergonomic risk level of a workstation is evaluated using a parameter called accumulated risk posture(ARP), which is calculated using rapid upper limb assessment(RULA) check sheet. This work is based on the case study of an MMAL problem in Rane(Madras) Ltd.(India), in which a problem based genetic algorithm(GA) has been proposed to minimize the mentioned objectives. The working of the genetic operators such as selection, crossover and mutation has been modified with respect to the addressed MMAL problem. The results show that there is a significant impact over productivity and the process time of the final assembled product, i.e., the rate of production is increased by 39.5% and the assembly time for one particular model is reduced to 13 min from existing 18 min. Also, the space required using the proposed assembly line is only 200 m2 against existing 350 m2. Further, the algorithm helps in reducing workers fatigue(i.e., ergonomic friendly).

A survey on assembly lines and its types

Assembly lines are useful for mass production of standard as well as customized products. Line balancing is an important issue, in this regard an optimal or near optimal balance can provide a fruitful savings in the initial cost and also in the running cost of such production systems. A survey of different problems in different types of assembly lines and some of the critical and on going research areas are highlighted here. The provided research information is momentous for the research community in assembly line area to proceed further in the presented issues of assembly lines.

Mixed-Model U-Shaped Assembly Line Balancing Problems with Coincidence Memetic Algorithm

Mixed-model U-shaped assembly line balancing problems (MMUALBP) is known to be NP-hard resulting in it being nearly impossible to obtain an optimal solution for practical problems with deterministic algorithms. This paper pre-sents a new evolutionary method called combinatorial optimisation with coincidence algorithm (COIN) being applied to Type I problems of MMUALBP in a just-in-time production system. Three objectives are simultaneously considered;minimum number workstations, minimum work relatedness, and minimum workload smoothness. The variances of COIN are also proposed, i.e. CNSGA II, and COIN-MA. COIN and its variances are tested against a well-known algo-rithm namely non-dominated sorting genetic algorithm II (NSGA II) and MNSGA II (a memetic version of NSGA II). Experimental results showed that COIN outperformed NSGA II. In addition, although COIN-MA uses a marginal CPU time than CNSGA II, its other performances are dominated.

Optimization of Energy Resource Management for Assembly Line Balancing Using Adaptive Current Search

This paper aimed to present the optimization of energy resource management in a car factory by the adaptive current search (ACS)—one of the most efficient metaheuristic optimization search techniques. Assembly lines of a specific car factory considered as a case study are balanced by the ACS to optimize their energy resource management. The workload variance of the line is performed as the objective function to be minimized in order to increase the productivity. In this work, the ACS is used to address the number of tasks assigned for each workstation, while the sequence of tasks is assigned by factory. Three real-world assembly line balancing (ALB) problems from a specific car factory are tested. Results obtained by the ACS are compared with those obtained by the genetic algorithm (GA), tabu search (TS) and current search (CS). As results, the ACS outperforms other algorithms. By using the ACS, the productivity can be increased and the energy consumption of the lines can be decreased significantly.

Strategic Robust Mixed Model Assembly Line Balancing Based on Scenario Planning

Assembly line balancing involves assigning a series of task elements to uniform sequential stations with certain restrictions. Decision makers often discover that a task assignment which is optimal with respect to a deterministic or stochastic/fuzzy model yields quite poor performance in reality. In real environments, assembly line balancing robustness is a more appropriate decision selection guide. A robust model based on the α worst case scenario is developed to compensate for the drawbacks of traditional robust criteria. A robust genetic algorithm is used to solve the problem. Comprehensive computational experiments to study the effect of the solution procedure show that the model generates more flexible robust solutions. Careful tuning the value of α allows the decision maker to balance robustness and conservativeness of as- sembly line task element assignments.

Pareto lexicographic a-robust approach and its application in robust multi objective assembly line balancing problem

Robustness in most of the literature is associated with rain-max or min-max regret criteria. However, these criteria of robustness are conservative and therefore recently new criteria called, lexicographic a- robust method has been introduced in literature which defines the robust solution as a set of solutions whose quality orjth largest cost is not worse than the best possible jth largest cost in all scenarios. These criteria might be significant for robust optimization of single objective optimization problems. However, in real optimization problems, two or more than two conflicting objectives are desired to optimize concurrently and solution of multi objective optimization problems exists in the form of a set of solutions called Pareto solutions and from these solutions it might be difficult to decide which Pareto solution can satisfy rain-max, min-max regret or lexico- graphic a-robust criteria by considering multiple objectives simultaneously. Therefore, lexicographic a-robust method which is a recently introduced method in literature is extended in the current research for Pareto solutions. The proposed method called Pareto lexicographic a-robust approach can define Pareto lexicographic a-robust solu- tions from different scenarios by considering multiple objectives simultaneously. A simple example and an application of the proposed method on a simple problem of multi objective optimization of simple assembly line balancing problem with task time uncertainty is presented to get their robust solutions. The presented method can be significant to implement on different multi objective robust optimization problems containing uncertainty.

An improved artificial bee colony algorithm with MaxTF heuristic rule for two-sided assembly line balancing problem

Two-sided assembly line is usually used for the assembly of large products such as cars,buses,and trucks.With the development of technical progress,the assembly line needs to be reconfigured and the cycle time of the line should be optimized to satisfy the new assembly process.Two-sided assembly line balancing with the objective of minimizing the cycle time is called TALBP-2.This paper proposes an improved artificial bee colony(IABC)algorithm with the MaxTF heuristic rule.In the heuristic initialization process,the MaxTF rule defines a new task's priority weight.On the basis of priority weight,the assignment of tasks is reasonable and the quality of an initial solution is high.In the IABC algorithm,two neighborhood strategies are embedded to balance the exploitation and exploration abilities of the algorithm.The employed bees and onlooker bees produce neighboring solutions in different promising regions to accelerate the convergence rate.Furthermore,a well-designed random strategy of scout bees is developed to escape local optima.The experimental results demonstrate that the proposed MaxTF rule performs better than other heuristic rules,as it can find the best solution for all the 10 test cases.A comparison of the IABC algorithm and other algorithms proves the effectiveness of the proposed IABC algorithm.The results also denote that the IABC algorithm is efficient and stable in minimizing the cycle time for the TALBP-2,and it can find 20 new best solutions among 25 large-sized problem cases.

Hybrid genetic algorithm for a type-Ⅱ robust mixed-model assembly line balancing problem with interval task times

The typemixed-model assembly line balancing problem with uncertain task times is a critical problem. This paper addresses this issue of practical significance to production efficiency. Herein, a robust optimization model for this problem is formulated to hedge against uncertainty. Moreover, the counterpart of the robust optimization model is developed by duality. A hybrid genetic algorithm (HGA) is proposed to solve this problem. In this algorithm, a heuristic method is utilized to seed the initial population. In addition, an adaptive local search procedure and a discrete Levy flight are hybridized with the genetic algorithm (GA) to enhance the performance of the algorithm. The effectiveness of the HGA is tested on a set of benchmark instances. Furthermore, the effect of uncertainty parameters on production efficiency is also investigated.

A Multi-Object Genetic Algorithm for the Assembly Line Balance Optimization in Garment Flexible Job Shop Scheduling

Numerous clothing enterprises in the market have a relatively low efficiency of assembly line planning due to insufficient optimization of bottleneck stations.As a result,the production efficiency of the enterprise is not high,and the production organization is not up to expectations.Aiming at the problem of flexible process route planning in garment workshops,a multi-object genetic algorithm is proposed to solve the assembly line bal-ance optimization problem and minimize the machine adjustment path.The encoding method adopts the object-oriented path representation method,and the initial population is generated by random topology sorting based on an in-degree selection mechanism.The multi-object genetic algorithm improves the mutation and crossover operations according to the characteristics of the clothing process to avoid the generation of invalid offspring.In the iterative process,the bottleneck station is optimized by reasonable process splitting,and process allocation conforms to the strict limit of the station on the number of machines in order to improve the compilation efficiency.The effectiveness and feasibility of the multi-object genetic algorithm are proven by the analysis of clothing cases.Compared with the artificial allocation process,the compilation efficiency of MOGA is increased by more than 15%and completes the optimization of the minimum machine adjustment path.The results are in line with the expected optimization effect.

Assembly Unit Resource Balancing Strategy based on Discrete Production Mode

Aiming at the characteristics of obvious block division and strong discreteness in the assembly production mode of electronic products,this paper proposes a composite U-shaped flexible assembly line model,and establishes a multi-objective optimization mathematical model on this basis.According to the characteristics of the model,the improved ranked positional weight(RPW)method is used to adjust the generation process of the initial solution of the genetic algorithm,so that the genetic algorithm can be applied to the block task model.At the same time,the adaptive cross mutation factor is used on the premise that tasks between different blocks are not crossed during cross mutation,which effectively improves the probability of excellent individuals retaining.After that,the algorithm is used to iterate to obtain the optimal solution task assignment.Finally,the algorithm results are compared with actual production data,which verifies the validity and feasibility of the assembly line model for discrete production mode proposed in this paper.

MODEL OF OPERATING AND BALANCING ASSEMBLY LINE IN A MASS CUSTOMIZATION ENVIRONMENT

The successful implementation of mass customization lies on reengineeringtechnology and management methods to organize the production. Especially in assembly phase, variousproduct configurations, due-time penalties and order-driven strategy challenge the traditionaloperation and management of assembly lines. The business features and the operation pattern ofassembly line based on mass customization are analyzed. And the research emphatically studiesvarious technologic factors to improve customer satisfaction and their corresponding implementmethods in operating assembly line. In addition, the models are proposed for operating assembly lineunder dynamic process environment in mass customization. A genetic approach is developed to providethe optimal solution to the models. The effectiveness of the proposed approach is evaluated with anindustrial application.