A mixed-integer programming model for cycle time minimization in assembly line balancing: Using rework stations for performing parallel tasks
In assembly lines, rework stations are generally used for reprocessing defective items. On the other hand, using rework stations for this purpose only might cause inefficient usage of the resources in this station especially in an assembly line with a low defective rate. In this study, a mixed-integer programming model for cycle time minimization is proposed by considering the use of rework stations for performing parallel tasks. By linearizing the non-linear constraint about parallel tasks using a variate transformation, the model is transformed to a linear-mixed-integer form. In addition to different defective rates, different rework station positions are also considered using the proposed model. The performance of the model is analyzed on several test problems from the related literature.
Altekin, F. T., Bayindir, Z. P., & Gümüskaya, V. (2016). Remedial actions for disassembly lines with stochastic task times. Computers & Industrial Engineering, 99, 78-96. https://doi.org/10.1016/j.cie.2016.06.027
Anderson, E. J., & Ferris, M. C. (1994). Genetic algorithms for combinatorial optimization: the assemble line balancing problem. ORSA Journal on Computing, 6(2), 161-173. https://doi.org/10.1287/ijoc.6.2.161
Askin, R. G., & Zhou, M. (1997). A parallel station heuristic for the mixed-model production line balancing problem. International Journal of Production Research, 35(11), 3095-3106. https://doi.org/ 10.1080/002075497194309
Bard, J. F. (1989). Assembly line balancing with parallel workstations and dead time. The International Journal of Production Research, 27(6), 1005-1018. https://doi.org/10.1080/00207548908942604
Bartholdi, J. J. (1993). Balancing two-sided assembly lines: a case study. International Journal of Production Research, 31(10), 2447-2461. https://doi.org/10.1080/00207549308956868
Battaia, O., & Dolgui, A. (2013). A taxonomy of line balancing problems and their solution approaches. International Journal of Production Economics, 142(2), 259-277. https://doi.org/10.1016/j.ijpe.2012.10.020
Baybars, I. (1986). A survey of exact algorithms for the simple assembly line balancing problem. Management science, 32(8), 909-932. https://doi.org/10.1287/mnsc.32.8.909
Baykasoglu, A., & Demirkol Akyol, S. (2014). Ergonomic assembly line balancing. Journal of the Faculty of Engineering and Architecture of Gazi University, 29(4), 785-792. https://doi.org/10.17341/gummfd.00296
Becker, C., & Scholl, A. (2006). A survey on problems and methods in generalized assembly line balancing. European journal of operational research, 168(3), 694-715. https://doi.org/10.1016/j.ejor.2004.07.023
Boysen, N., Fliedner, M., & Scholl, A. (2007). A classification of assembly line balancing problems. European journal of operational research, 183(2), 674-693. https://doi.org/10.1016/j.ejor.2006.10.010
Bryton, B. (1954). Balancing of a continuous production line. Master’s Thesis, Northwestern University, Evanston.
Cercioglu, H., Ozcan, U., Gokcen, H., & Toklu, B. (2009). A simulated annealing approach for parallel assembly line balancing problem. Journal of the Faculty of Engineering and Architecture of Gazi University, 24(2), 331-341.
Efe, B., Kremer, G. E. O., & Kurt, M. (2018). Age and gender-based workload constraint for assembly line worker assignment and balancing problem in a textile firm. International Journal of Industrial Engineering, 25(1), 1-17.
Ghosh, S., & Gagnon, R. J. (1989). A comprehensive literature review and analysis of the design, balancing and scheduling of assembly systems. The International Journal of Production Research, 27(4), 637-670. https://doi.org/10.1080/00207548908942574
Gokcen, H., & Baykoc, Ö. F. (1999). A new line remedial policy for the paced lines with stochastic task times. International Journal of Production Economics, 58(2), 191-197. https://doi.org/10.1016/S0925-5273(98)00123-6
Gokcen, H., Agpak, K., & Benzer, R. (2006). Balancing of parallel assembly lines. International Journal of Production Economics, 103(2), 600-609. https://doi.org/10.1016/j.ijpe.2005.12.001
Guner, B., & Hasgul, S. (2012). U-Type assembly line balancing with ergonomic factors for balance stability. Journal of the Faculty of Engineering and Architecture of Gazi University, 27(2), 407-415.
Kaplan, O. (2004). Assembly line balancing with task paralleling. Master’s Thesis, METU, Ankara.
Kara, Y., Ozguven, C., Yalcın, N., & Atasagun, Y. (2011). Balancing straight and U-shaped assembly lines with resource dependent task times. International Journal of Production Research, 49(21), 6387-6405. https://doi.org/10.1080/00207543.2010.535039
Kara, Y., Atasagun, Y., Gokcen, H., Hezer, S., & Demirel, N. (2014). An integrated model to incorporate ergonomics and resource restrictions into assembly line balancing. International Journal of Computer Integrated Manufacturing, 27(11), 997-1007. https://doi.org/10.1080/0951192X.2013.874575
Kazemi, S. M., Ghodsi, R., Rabbani, M., & Tavakkoli-Moghaddam, R. (2011). A novel two-stage genetic algorithm for a mixed-model U-line balancing problem with duplicated tasks. The International Journal of Advanced Manufacturing Technology, 55(9-12), 1111-1122. https://doi.org/10.1007/s00170-010-3120-6
Kim, Y. K., Kim, Y., & Kim, Y. J. (2000). Two-sided assembly line balancing: a genetic algorithm approach. Production Planning & Control, 11(1), 44-53. https://doi.org/10.1080/095372800232478
Kottas, J. F., & Lau, H. S. (1976). A total operating cost model for paced lines with stochastic task times. AIIE Transactions, 8(2), 234-240. https://doi.org/10.1080/05695557608975072
Lau, H. S., & Shtub, A. (1987). An exploratory study on stopping a paced line when incompletions occur. IIE transactions, 19(4), 463-467. https://doi.org/10.1080/07408178708975421
Lee, T. O., Kim, Y., & Kim, Y. K. (2001). Two-sided assembly line balancing to maximize work relatedness and slackness. Computers & Industrial Engineering, 40(3), 273-292. https://doi.org/10.1016/S0360-8352(01)00029-8
Mutlu, O., & Ozgormus, E. (2012). A fuzzy assembly line balancing problem with physical workload constraints. International Journal of Production Research, 50(18), 5281-5291. https://doi.org/10.1080/00207543.2012.709647
Ozcan, U., & Toklu, B. (2010). Balancing two-sided assembly lines with sequence-dependent setup times. International Journal of Production Research, 48(18), 5363-5383. https://doi.org/10.1080/00207540903140750
Pinto, P., Dannenbring, D. G., & Khumawala, B. M. (1975). A branch and bound algorithm for assembly line balancing with paralleling. The International Journal of Production Research, 13(2), 183-196. https://doi.org/10.1080/00207547508942985
Sabuncuoglu, I., Erel, E., & Alp, A. (2009). Ant colony optimization for the single model U-type assembly line balancing problem. International Journal of Production Economics, 120(2), 287-300. https://doi.org/10.1016/j.ijpe.2008.11.017
Salveson, M. E. (1955). The assembly line balancing problem. The Journal of Industrial Engineering, 18-25.
Scholl, A., & Becker, C. (2006). State-of-the-art exact and heuristic solution procedures for simple assembly line balancing. European Journal of Operational Research, 168(3), 666-693. https://doi.org/10.1016/j.ejor.2004.07.022
Shtub, A. (1984). The effect of incompletion cost on line balancing with multiple manning of work stations. The International Journal of Production Research, 22(2), 235-245. https://doi.org/10.1080/00207548408942450
Silverman, F. N., & Carter, J. C. (1986). A cost-based methodology for stochastic line balancing with intermittent line stoppages. Management Science, 32(4), 455-463. https://doi.org/10.1287/mnsc.32.4.455
Simaria, A. S., & Vilarinho, P. M. (2001). The simple assembly line balancing problem with parallel workstations-a simulated annealing approach. Int J Ind Eng-Theory, 8(3), 230-240.
Sivasankaran, P., & Shahabudeen, P. (2014). Literature review of assembly line balancing problems. The International Journal of Advanced Manufacturing Technology, 73(9-12), 1665-1694. https://doi.org/10.1007/s00170-014-5944-y
Suer, G. A. (1998). Designing parallel assembly lines. Computers & industrial engineering, 35(3-4), 467-470. https://doi.org/10.1016/S0360-8352(98)00135-1
Suwannarongsri, S., & Puangdownreong, D. (2008). Optimal assembly line balancing using tabu search with partial random permutation technique. International Journal of Management Science and Engineering Management, 3(1), 3-18. https://doi.org/10.1080/17509653.2008.10671032
Tiacci, L., Saetta, S., & Martini, A. (2006). Balancing mixed-model assembly lines with parallel workstations through a genetic algorithm approach. International Journal of Industrial Engineering, 13(4), 402.
Ugurdag, H. F., Rachamadugu, R., & Papachristou, C. A. (1997). Designing paced assembly lines with fixed number of stations. European Journal of Operational Research, 102(3), 488-501. https://doi.org/10.1016/S0377-2217(96)00248-2
Wei, N. C., & Chao, I. M. (2011). A solution procedure for type E simple assembly line balancing problem. Computers & Industrial Engineering, 61(3), 824-830. https://doi.org/10.1016/j.cie.2011.05.015
Metrics powered by PLOS ALM
This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives- 4.0 International License
Universitat Politècnica de València
e-ISSN: 2340-4876 ISSN: 2340-5317 https://doi.org/10.4995/ijpme