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Balancing of mixed-model parallel U-shaped assembly lines considering model sequences

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  • Ibrahim Kucukkoc
  • David Z. Zhang

Abstract

As a consequence of increasing interests in customised products, mixed-model lines have become the most significant components of today’s manufacturing systems to meet surging consumer demand. Also, U-shaped assembly lines have been shown as the intelligent way of producing homogeneous products in large quantities by reducing the workforce need thanks to the crossover workstations. As an innovative idea, we address the mixed-model parallel U-shaped assembly line design which combines the flexibility of mixed-model lines with the efficiency of U-shaped lines and parallel lines. The multi-line stations utilised in between two adjacent lines provide extra efficiency with the opportunity of assigning tasks into workstations in different combinations. The new line configuration is defined and characterised in details and its advantages are explained. A heuristic solution approach is proposed for solving the problem. The proposed approach considers the model sequences on the lines and seeks efficient balancing solutions for their different combinations. An explanatory example is also provided to show the sophisticated structure of the studied problem and explain the running mechanism of the proposed approach. The results of the experimental tests and their statistical analysis indicated that the proposed line design requires fewer number of workstations in comparison with independently balanced mixed-model U-lines.

Suggested Citation

  • Ibrahim Kucukkoc & David Z. Zhang, 2017. "Balancing of mixed-model parallel U-shaped assembly lines considering model sequences," International Journal of Production Research, Taylor & Francis Journals, vol. 55(20), pages 5958-5975, October.
    • Handle: RePEc:taf:tprsxx:v:55:y:2017:i:20:p:5958-5975
    DOI: 10.1080/00207543.2017.1312586
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    References listed on IDEAS

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    1. Nick T. Thomopoulos, 1967. "Line Balancing-Sequencing for Mixed-Model Assembly," Management Science, INFORMS, vol. 14(2), pages 59-75, October.
    2. G. J. Miltenburg & J. Wijngaard, 1994. "The U-line Line Balancing Problem," Management Science, INFORMS, vol. 40(10), pages 1378-1388, October.
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    4. Sabuncuoglu, Ihsan & Erel, Erdal & Alp, Arda, 2009. "Ant colony optimization for the single model U-type assembly line balancing problem," International Journal of Production Economics, Elsevier, vol. 120(2), pages 287-300, August.
    5. Kim, Yeo Keun & Kim, Jae Yun & Kim, Yeongho, 2006. "An endosymbiotic evolutionary algorithm for the integration of balancing and sequencing in mixed-model U-lines," European Journal of Operational Research, Elsevier, vol. 168(3), pages 838-852, February.
    6. Urban, Timothy L. & Chiang, Wen-Chyuan, 2006. "An optimal piecewise-linear program for the U-line balancing problem with stochastic task times," European Journal of Operational Research, Elsevier, vol. 168(3), pages 771-782, February.
    7. Kucukkoc, Ibrahim & Zhang, David Z., 2014. "Mathematical model and agent based solution approach for the simultaneous balancing and sequencing of mixed-model parallel two-sided assembly lines," International Journal of Production Economics, Elsevier, vol. 158(C), pages 314-333.
    8. Timothy L. Urban, 1998. "Note. Optimal Balancing of U-Shaped Assembly Lines," Management Science, INFORMS, vol. 44(5), pages 738-741, May.
    9. Miltenburg, John, 2001. "U-shaped production lines: A review of theory and practice," International Journal of Production Economics, Elsevier, vol. 70(3), pages 201-214, April.
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    Cited by:

    1. Raphael Kramer & Mauro Dell’Amico & Manuel Iori, 2017. "A batching-move iterated local search algorithm for the bin packing problem with generalized precedence constraints," International Journal of Production Research, Taylor & Francis Journals, vol. 55(21), pages 6288-6304, November.
    2. Boysen, Nils & Schulze, Philipp & Scholl, Armin, 2022. "Assembly line balancing: What happened in the last fifteen years?," European Journal of Operational Research, Elsevier, vol. 301(3), pages 797-814.
    3. Battaïa, Olga & Dolgui, Alexandre, 2022. "Hybridizations in line balancing problems: A comprehensive review on new trends and formulations," International Journal of Production Economics, Elsevier, vol. 250(C).
    4. Karim Aroui & Gülgün Alpan & Yannick Frein, 2017. "Minimising work overload in mixed-model assembly lines with different types of operators: a case study from the truck industry," International Journal of Production Research, Taylor & Francis Journals, vol. 55(21), pages 6305-6326, November.

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