Assembly Line Balancing with Processing Alternatives: An Application
AbstractThe conventional approach to the assembly line balancing problem assumes that the manufacturing methods to be used have been predetermined. However, in practice the design engineer has several alternatives available in the choice of processing, typically involving a trade-off between labor or capital intensive options. The choice of manufacturing method is frequently viewed as an investment or capital budgeting decision, contrasting projected savings in labor cost with the additional fixed cost for the more capital intensive alternatives. The manufacturing tasks (based on the selected processing alternatives) are then assigned to work stations so as to minimize the number of work stations (i.e., labor costs) necessary to achieve a desired production rate. This paper describes a method of simultaneously considering both the choice of manufacturing alternatives and the assignment of tasks to stations so as to minimize total costs (labor and fixed) over the expected life of the production line. The importance of considering these decisions jointly results from the fact that the benefits obtained from specific manufacturing alternatives should not be limited to anticipated labor savings alone. The true measure of achievable labor savings can only be determined after an assignment of tasks to stations has been chosen. For instance, although a processing alternative may reduce the total work content of a set of tasks, if the resulting line balancing assignment does not reduce the number of stations required to achieve a desired production rate, the assumed savings will not be achievable and will serve only to increase the idle time of the line. On the other hand, an apparently trivial reduction in the time to complete a certain task may lead to a more efficiently balanced line, producing a much greater real savings in labor cost than had been anticipated, due to a reduction in both work content and idle time for the line. The combined processing alternative line balancing problem can be formulated as an integer programming problem. Two alternate formulations are provided which differ in the degree of flexibility in selecting a cycle time. A branch and bound procedure is described for the fixed cycle time situation which takes advantage of the special structure of the problem to provide an efficient method capable of solving problems of practical interest. The effectiveness of the proposed procedure is demonstrated by application to an actual redesign of an assembly line for a major auto-industry supplier.
Download InfoIf you experience problems downloading a file, check if you have the proper application to view it first. In case of further problems read the IDEAS help page. Note that these files are not on the IDEAS site. Please be patient as the files may be large.
Bibliographic InfoArticle provided by INFORMS in its journal Management Science.
Volume (Year): 29 (1983)
Issue (Month): 7 (July)
production/scheduling: line balancing; finance: capital budgeting; programming: integer algorithms; branch and bound;
You can help add them by filling out this form.
CitEc Project, subscribe to its RSS feed for this item.
- Boysen, Nils & Fliedner, Malte & Scholl, Armin, 2008.
"Assembly line balancing: Which model to use when,"
International Journal of Production Economics,
Elsevier, vol. 111(2), pages 509-528, February.
- Armin Scholl & Nils Boysen & Malte Fliedner, 2008. "Optimally solving the Alternative Subgraphs Assembly Line Balancing Problem," Jena Research Papers in Business and Economics - Working and Discussion Papers 05/2008, Friedrich-Schiller-University Jena, School of Economics and Business Administration.
- Nils Boysen & Malte Fliedner & Armin Scholl, 2006. "Produktionsplanung bei Variantenfließfertigung: Planungshierarchie und Hierarchische Planung," Jenaer Schriften zur Wirtschaftswissenschaft 22/2006, Friedrich-Schiller-Universität Jena, Wirtschaftswissenschaftliche Fakultät.
- Gamberi, M. & Gamberini, R. & Manzini, R. & Regattieri, A., 2008. "An analytical model to evaluating the implementation of a batch-production-oriented line," International Journal of Production Economics, Elsevier, vol. 111(2), pages 729-740, February.
- Pinnoi, Anulark & Wilhelm, Wilbert E., 2000. "Valid inequalities for a class of assembly system problems," European Journal of Operational Research, Elsevier, vol. 126(1), pages 31-50, October.
- Araújo, Felipe F.B. & Costa, Alysson M. & Miralles, Cristóbal, 2012. "Two extensions for the ALWABP: Parallel stations and collaborative approach," International Journal of Production Economics, Elsevier, vol. 140(1), pages 483-495.
- Hsiu-Hsueh Kao & Din-Horng Yeh & Yi-Hsien Wang, 2011. "Resource Constrained Assembly Line Balancing Problem Solved with Ranked Positional Weight Rule," Review of Economics & Finance, Better Advances Press, Canada, vol. 1, pages 71-80, November.
For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: (Mirko Janc).
If references are entirely missing, you can add them using this form.