Assembly line balancing problem with skilled and unskilled workers: The advantages of considering multi-manned workstations

Document Type: IIEC 2020

Authors

1 Department of computer engineering, Faculty of Engineering, Gilan-e-Gharb Branch, Islamic Azad University, Gilan-e-Gharb, Iran

2 Department of industrial Engineering, Faculty of engineering management, Kermanshah University of Technology, Kermanshah, Iran

Abstract

This paper address a special class of generalized assembly line balancing in which it is assumed that there are two groups of workers: skilled and unskilled ones. The skilled workers are hired permanently while the unskilled ones can be hired temporarily in order to meet the seasonal demands. It is also assumed that more than one worker may be assigned to each workstation. To show the advantages of assigning several workers instead of single workers to each workstation in such a class of problem, a mixed integer programming formulation is presented. This model minimizes the number of temporary workers on the line as the first objective and the number of workstations as the secondary one while cycle time and the number of permanent workers are fixed. The proposed formulation is applied to solve some experimental instances found in the literature. The comparison between the optimal solutions of the proposed model and those of traditional assembly lines with a single-manned workstation indicates that our model has been able to reduce the line length on average of 24.40 per cent while the number of unskilled workers remains optimal. 

Keywords

Main Subjects


Battaïa, O., and Dolgui, A. (2013). A taxonomy of line balancing problems and their solution approaches. International Journal of Production Economics, 142(2), 259-277.

 

Baybars, I., 1986. A survey of exact algorithms for the simple assembly line balancing problem.  Management science, 32(8), 909-932.

 

Becker, C. and Scholl, A. (2006). A survey on problems and methods in generalized assembly line balancing. European Journal of Operational Research, 168(3), 694-715.

 

Becker, C. and Scholl, A. (2009). Balancing assembly lines with variable parallel workplaces: Problem definition and effective solution procedure. European Journal of Operational Research, 199(2), 359-374.

 

Bowman EH (1960) Assembly line balancing by linear programming. Operations Research, 8, 385–389.

 

Chang, H.-J., and Chang, T.-M. (2010). Simultaneous Perspective-based Mixed-model Assembly Line Balancing Problem. Tamkang Journal of Science and Engineering, 13, 327-336.

 

Cevikcan, E., Durmusoglu, M.B., and Unal, M.E. (2009). A team-oriented design methodology for mixed model assembly systems. Computers & Industrial Engineering, 56(2), 576-599.

 

Corominas, A., Pastor, R., & Plans, J. (2008). Balancing assembly line with skilled and unskilled workers. Omega, 36(6), 1126-1132.

 

Dimitriadis, S.G. (2006). Assembly line balancing and group working: A heuristic procedure for workers' groups operating on the same product and workstation. Computers & Operations Research 33(9), 2757-2774.

Fattahi, P., and Roshani, A. and Roshani, A. (2011). A mathematical model and ant colony algorithm for multi-manned assembly line balancing problem. The International Journal of Advanced Manufacturing Technology, 53 (1-4), 363-378.

 

Jackson JR (1956) A computing procedure for a line balancing problem. Management Science, 2, 261–272.

 

Jaeschke G (1964) Eine allgemaine Methode Zur Losung Kombinatoriiicher Probleme. Ablauf-Plan Forsch, 5,133–153.

 

Kellegöz, T. (2017). Assembly line balancing problems with multi-manned stations: a new mathematical formulation and Gantt based heuristic method. Annals of Operations Research, 253(1), 377-404.

 

Kellegoz, T. and Toklu, B. (2012). An efficient branch and bound algorithm for assembly line balancing problems with parallel multi-manned workstations. Computers & Operations Research, 39(12), 3344-3360.

 

Kellegoz, T. and Toklu, B. (2015). A priority rule-based constructive heuristic and an improvement method for balancing assembly lines with parallel multi-manned workstations. International Journal of Production Research, 53(3), 736-756.

 

Kim, D., Moon, D.H., Moon, I., (2018). Balancing a mixed-model assembly line with unskilled temporary workers: algorithm and case study, Assembly Automation, https://doi.org/10.1108/AA-06-2017-070.

 

Mansoor EM (1964) Assembly line balancing-An Improvement on the Ranked Positional Weight Technique. Journal of Industrial Engineering, 15, 73–77.

 

Merten P (1967) Assembly line balancing by partial enumeration. Ablauf- und planungsforschung, 429-433.

 

Moon, I., Shin, S. and Kim, D., (2014), Integrated assembly line balancing with skilled and unskilled workers. IFIP International Conference on Advances in Production Management Systems, 459-466. Springer, Berlin, Heidelberg.

 

Roshani, A. and Giglio, D., (2015). A Mathematical Programming Formulation for Cost-oriented Multi-manned Assembly Line Balancing Problem. IFACPapersOnLine, 48(3), 2293-2298.

 

Roshani, A. and Giglio, D., (2015). A simulated annealing approach for multi-manned assembly line balancing problem type II. IFAC-PapersOnLine 48(3), 2299-2304.

 

Roshani, A., & Giglio, D. (2017). Simulated annealing algorithms for the multi-manned assembly line balancing problem: minimising cycle time. International Journal of Production Research, 55(10), 2731-2751.

 

Roshani, A., Paolucci, M., Giglio, D, and Tonelli, F., (2020) A hybrid adaptive variable neighbourhood search approach for multi-sided assembly line balancing problem to minimise the cycle time, International Journal of Production Research, DOI: 10.1080/00207543.2020.1749958

 

Roshani, A., Roshani, A., Roshani, A., Salehi, M., and Esfandyari, A. (2013). A simulated annealing algorithm for multi-manned assembly line balancing problem. Journal of Manufacturing Systems, 32(1), 238-247.

Salveson, M.E. (1955). The assembly line balancing problem. Journal of industrial engineering, 6(3), 18-25.

 

Sahin, M., Kellegz, T., (2019). A new mixed-integer linear programming formulation and particle swarm optimization based hybrid heuristic for the problem of resource investment and balancing of the assembly line with multi-manned workstations. Computers & Industrial Engineering, 133, 107 - 120.

 

Tonelli, F., Paolucci, M., Anghinolfi, D. and Taticchi, P. (2013). Production planning of mixed-model assembly lines: a heuristic mixed integer programming based approach. Production Planning & Control, 24(1), 110-127.

 

Yilmaz H. and Yilmaz M. 2015. Multi-manned assembly line balancing problem with balanced load density. Assembly Automation, 35(1), 137-142.