Professional Documents
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Volume 13 Issue 2 Version 1.0 Year 2013
Type: Double Blind Peer Reviewed International Research Journal
Publisher: Global Journals Inc. (USA)
Online ISSN: 2249-4596 Print ISSN:0975-5861
2013. Naveen Kumar & Dalgobind Mahto. This is a research/review paper, distributed under the terms of the Creative
Commons Attribution-Noncommercial 3.0 Unported License http://creativecommons.org/licenses/by-nc/3.0/), permitting all non
commercial use, distribution, and reproduction in any medium, provided the original work is properly cited.
Assembly Line Balancing: A Review of
Developments and Trends in Approach to
Industrial Application
Naveen Kumar & Dalgobind Mahto
Year 2 013
to be assigned to workstations, so that the predetermined goal
is achieved. Minimization of the number of workstations and i. Line Balancing
maximization of the production rate are the most common Line Balancing is leveling the workload across
goals. This paper presents the reviews of different works in the
all processes in a cell or value stream to remove
area of assembly line balancing and tries to find out latest
developments and trends available in industries in order to bottlenecks and excess capacity. A constraint slows the 29
minimize the total equipment cost and number of process down and results if waiting for downstream
L
ine Balancing means balancing the production products will attract customers without any difference
line, or any assembly line. The main objective of and allows the profitable utilization of Assembly Lines.
line balancing is to distribute the task evenly over An advanced technology of production which enables
the work station so that idle time of man of machine can the automated setup of operations and it is negotiated
be minimized. Lime balancing aims at grouping the time and money. Once the product is assembled in the
facilities or workers in an efficient pattern in order to same line and it wont variant the setup or significant
obtain an optimum or most efficient balance of the setup and its time that is used, this assembly system is
capacities and flows of the production or assembly called as Single Model Line.
30
Figure 1 : Assembly lines for single and multiple products
D ) Volume XIII Issuev vII Version I
Number of
Single Model
models Mixed Model Multi Model
Unpaced
Line control
Paced asynchronous Unpaced synchronous
Level of
Global Journal of Researches in Engineering ( G
LEVELS
Product 1 2
Sub-assemblies 1 2 3 4 5
Components 1 2 3 4
Raw Material 1 2 3 4
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Costs which are associated with the inventory are (eq.1)
space, obsolescence, damage, opportunity cost,
lagged defect detection and handling. In the case of
ii. Lead Time
obsolete inventory, all costs invested in the production
Summation of production times along the
of a part are wasted. Excessive inventory should be 31
assembly line.
eliminated.
vii. Smoothness Index STmax - maximum station time (in most cases cycle
This is the index to indicate the relative time),
smoothness of a given assembly line balance. A STi - station time of station i.
smoothness indeed is zero indicates perfect balance.
viii. Balance Delay
This is the ratio of total station time to the
(eq.4) product of cycle time and the number of workstations.
Where,
(eq.5)
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The aims and objectives of the present study the requirements and qualifications to fulfill the work. In
are as follows:- this work a short problem description was presented
x To reduce production cost and improve productivity along with classification of existent and new heuristic
x To determine number of feasible workstation. methods for solving this problem. A new priority rule
x To identify the location of bottleneck and eliminate called best change of idle cost was proposed. This
them. priority rule differs from the existent priority rules
x To determine machinery and equipment according because it was the only one which considers that
to assembly mechanism. production cost were the result of both, production time
and cost rates.
x To equally distribute the workloads among workmen
A work on new heuristic method for mixed
to the assembly line.
model assembly line balancing problem was published
x To optimize the production functions through
by Jin and Wu (2002) [3]. A goal chasing method was
construction of mix form of automation assembly
presented which is a popular algorithm in JIT system for
and manual assembly.
Global Journal of Researches in Engineering ( G
considered in a mixed-model line which was operated balancing problem for minimizing stations and task
under a cyclic sequencing approach. Study of the duplication costs. A common assumption in the
problem was done in an assembly line environment with literature on mixed model assembly line balancing is
synchronous transfer of parts between the stations. that a task that is common to multiple models must be
They formulated the assembly line balancing problem assigned to a single station. In this work a common task
with the objective of minimizing total cycle time by to be assigned to different stations for different models.
incorporating the cyclic sequencing information. They The sum of costs of the stations and the task duplication
showed that the solution of a mathematical model that was to be minimized. An optimal solution procedure
combines multiple models into a single one by adding based on a backtracking branch and bound algorithm
up operation times constitutes a lower bound for this was developed and evaluates its performance via a
formulation. An alternative formulation was proposed large set of experiments. For solving large-scale
that suggested minimizing the maximum sub cycle time. problems branch and bound based heuristic was
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A work was presented by Simaria and Vilarinho developed.
(2004) [6] on genetic algorithm based approach to the Levitin et al. (2006) [11] works on genetic
mixed-model assembly line balancing problem of type II. algorithm for robotic assembly line balancing. Flexibility
According to them mixed-model assembly lines allow for and automation in assembly lines can be achieved by
the simultaneous assembly of a set of similar models of the use of robots. The robotic assembly line balancing 33
a product. A mathematical programming model was (RALB) problem was defined for robotic assembly line,
method was based on the integration of a multi-attribute balancing problem which had some restricting
decision making procedure, named technique for order assumptions. Recently, a lot of research work had been
preference by similarity to ideal solution (TOPSIS), and done in order to describe and solve more realistic
the well known Kottas and Lau heuristic approach. The generalized problems.
proposed methodology was focused on rebalancing an Kim et al. (2006) [18] presented his work on
existing line, when some changes in the input endo symbiotic evolutionary algorithm for the integration
parameters (i.e. product characteristics and cycle time) of balancing and sequencing in mixed-model U-lines. A
occur. Hence, the algorithm deals with the assembly line new evolutionary approach in mixed model U-shaped
balancing problem by considering the minimization of lines was proposed to deal with both balancing and
two performance criteria: (i) the unit labor and expected sequencing problems. The use of U-shaped lines was
unit incompletion costs, & (ii) tasks reassignment. an important element in Just-In-Time production. For an
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A work was presented by Song (2006) [15] on efficient operation of the lines, it is important to have a
recursive operator allocation approach for assembly proper line balancing and model sequencing. A new
line-balancing optimization problem with the genetic approach was proposed to solve the two
consideration of operator efficiency. An optimization problems of line balancing and model sequencing
34 model was used for assembly line balancing problem in called endosymbiotic evolutionary algorithm.
order to improve the line balance of a production line Peeters and Degraeve (2006) [19] works on
under a human centric and dynamic apparel assembly linear programming based lower bound for the simple
D ) Volume XIII Issuev vII Version I
process. An approach was proposed to balance assembly line balancing problem. The simple assembly
production line through optimal operator allocation with line balancing problem was a classical integer
the consideration of operator efficiency. Two recursive programming problem in operations research. A set of
algorithms were developed to generate all feasible tasks, each one being an indivisible amount of work
solutions for operator allocation. Three objectives i.e. the requiring a number of time units, must be assigned to
lowest standard deviation of operation efficiency, the workstations without exceeding the cycle time. They
highest production line efficiency and the least total presented a new lower bound, namely the LP relaxation
operation efficiency waste were rearranged to find out of an integer programming formulation based on
the optimal solution of operator allocation. The DantzigWolfe decomposition. A column generation
performance comparison demonstrated that the algorithm was proposed to solve the formulation and a
proposed optimization method outperforms the industry branch-and-bound algorithm also proposed to exactly
practice. solve the pricing problem.
Dolgui et al. (2006) [16] works on special case A work on optimal piecewise-linear program for
Global Journal of Researches in Engineering ( G
of transfer lines balancing by graph approach. In their the U-line balancing problem with stochastic task times
work for paced production they considered a balancing was published by Urban and Chiang (2006) [20]. The
problem lines with workstations in series and blocks of utilization of U-shaped layouts in place of the traditional
parallel operations at the workstations. Operations of straight-line configuration has become increasingly
each workstation were partitioned into blocks. All popular. This work examines the U-line balancing
operations of the same block were performed problem with stochastic task times. A chance-
simultaneously by one spindle head. All blocks of the constrained, piecewise linear, integer program was
same workstation were also executed simultaneously. formulated to find the optimal solution. Various
The operation time of the workstation was the maximal approaches were used to identify a tight lower bound.
value among operation times of its blocks. The line cycle Computational results showed that the proposed
time was the maximal workstation time. A method for method was able to solve practical sized problems.
solving the problem was based on its transformation to Hirotani et al. (2006) [21] works on analysis and
a constrained shortest path problem. design of self-balancing production line. In a self-
A survey on problems and methods in balancing production line each worker was assigned
generalized assembly line balancing was presented by work dynamically. In this work, they examine other less
Becker and Scholl (2006) [17]. Assembly lines are restrictive conditions that can achieve the same self-
traditional and still attractive means of mass and large balancing effect, and furthermore, characteristics of this
scale series production. Since the early times of Henry line were analyzed by deriving the imbalance condition
Ford several developments took place which changed and analyzing the influence of initial position. In addition,
assembly lines from strictly paced and straight single- a method for designing a self-balancing line based on
model lines to more flexible systems including, among our results was proposed.
others, lines with parallel work stations or tasks, A work was presented by Dimitriadis (2006) [22]
customer oriented mixed model and multi-model lines, on assembly line balancing and group working: A
U-shaped lines as well as un paced lines with heuristic procedure for workers groups operating on the
intermediate buffers. Assembly line balancing research same product and workstation. In this work they
had traditionally focused on the simple assembly line examined an assembly line balancing problem that
differs from the conventional one in the sense that there completion. Once a job has been assigned to a
were multi-manned workstations, where workers groups machine it cannot be reassigned to another machine.
simultaneously perform different assembly works on the Focus was to minimize the maximum over time of the
same product and workstation. The proposed approach sum (over all machines) of the squares of the loads,
here results in shorter physical line length and instead of the traditional maximum load.
production space utilization improvement, because the A state-of-the-art exact and heuristic solution
same number of workers can be allocated to fewer procedure for simple assembly line balancing was
workstations. A heuristic assembly line balancing presented by Scholl and Becker (2006) [27]. Whenever
procedure was thus developed and illustrated. Finally, a line has to be configured or redesigned the assembly
experimental results of a real-life automobile assembly line balancing problem arises there and had to be
plant case and well known problems from the literature solved. It can be distributing of the total workload for
indicate the effectiveness and applicability of the manufacturing. In this work, they an up-to-date and
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proposed approach in practice. comprehensive survey of simple assembly line
Lapierre et al. (2006) [23] presented his work on balancing problem research with a special emphasis on
balancing assembly lines with tabu search. Balancing recent outstanding and guiding contributions to the field
assembly lines is a crucial task for manufacturing had been given.
companies in order to improve productivity and A balancing method and genetic algorithm for 35
minimize production costs. Despite some progress in disassembly line balancing was developed by
model of one of its variants. An ant algorithm was the global workstation time. After formulating a
presented that offered good results with simple mathematical model for this innovative problem and
balancing problems. Finally, the validity of the proposed showing the high combinatorial nature of the problem,
algorithms was tested by means of a computational eight different heuristic rules and a GRASP algorithm
experience with reference instances. were designed and tested for solving the problem in
A station-oriented enumerative algorithm for reasonable computational time.
two-sided assembly line balancing was developed by Miralles et al. (2008) [37] works on Branch and
Xia-o-feng et al. (2008) [32]. A station-oriented bound procedures for solving the Assembly Line Worker
enumerative algorithm for two-sided assembly lines Assignment and Balancing Problem: Application to
balancing was proposed in this work. Firstly the time Sheltered Work centers for Disabled. In this work a new
transfer function was defined and combined with the problem called Assembly Line Worker Assignment and
Year 2013
precedence relation to compute the earliest and the Balancing Problem (ALWABP) was introduced. The
latest start time of tasks. With the direction and cycle problem consists of providing a simultaneous solution to
time constraints, a station-oriented procedure based on a double assignment: (1) tasks to stations; and (2)
the start time was designed to assign tasks, starting available workers to stations. After defining the
36 from the left station to the right station of the position. mathematical model for this problem, a basic Branch
The proposed algorithm was integrated with the and Bound approach with three possible search
Hoffmann heuristic to develop a system for solving two-
D ) Volume XIII Issuev vII Version I
Eryuruk et al. (2008) [34]. In this two heuristic assembly later. They showed that polynomial solutions can be
line balancing techniques known as the Ranked obtained for both simple assembly line balancing
Positional Weight Technique developed by Helgeson problem and U-type line balancing problem with
and Birnie, and the Probabilistic Line Balancing learning effect. A dynamic programming based heuristic
Technique developed by El-Sayed and Boucher, were for the assembly line balancing problem was presented
applied to solve the problem of multi-model assembly by Bautista and Pereira (2009) [39]. The simple
line balancing in a clothing company for two models. assembly line balancing problem was the simplification
Boysen et al. (2008) [35] in their work on of a real problem associated to the assignment of the
assembly line balancing tried to make understand that elementary tasks required for assembly of a product in
which model to use when. This work structures the vast an assembly line. The present work proposes a new
field of assembly line balancing according to procedure to solve the problem named Bounded
characteristic practical settings and highlights relevant Dynamic Programming. This use of the term Bounded
model extensions which were required to reflect real- was associated not only with the use of bounds to
world problems and open research challenges were reduce the state space but also to the reduction of such
identified. Balancing and scheduling tasks in assembly space based on heuristics.
was done by Andres et al. (2008) [36] lines with Choi (2009) [40] presented a work on goal
sequence-dependent setup times. According to them programming mixed-model line balancing for
the classical Simple Assembly Line Balancing Problem processing time and physical workload. They present a
(SALBP) has been widely enriched over the past few new mathematical model of line balancing for
years with many realistic approaches and much effort processing time and physical workload at the same
has been made to reduce the distance between the time. According to them line balancing was the problem
academic theory and the industrial reality. The problem to assign tasks to stations while satisfying some
presented in this work adds sequence-dependent setup managerial viewpoints. Comparing the pay offs between
time considerations to the classical SALBP and when- the two overloads, test results showed that well
ever a task is assigned next to another at the same balanced job allocation was able to be obtained through
workstation, a setup time must be added to compute the proposed model. And they conclude that the model
may be very useful for the operation managers to make approach a branch and bound procedure was
decisions on their job scheduling efforts. proposed which also can be applied as a heuristic.
A mathematical model and a genetic algorithm Balancing of mixed-model two-sided assembly
for two-sided assembly line balancing were presented lines was presented by Ozcan and Toklu (2009) [47]. A
by Kim (2009) [41]. A two-sided assembly line is a type new mathematical model and a simulated annealing
of production line where tasks are performed in parallel algorithm for the mixed model two-sided assembly line
at both sides of the line. The line is often found in balancing problem had been presented. The proposed
producing large products such as trucks and buses. In mathematical model minimizes the number of mated-
this they presented a mathematical model and a genetic stations as the primary objective and minimizes the
algorithm (GA) for two-sided assembly line balancing. number of stations as a secondary objective for a given
The mathematical model can be used as a foundation cycle time. In the proposed simulated annealing
for further practical development in the design of two- algorithm, two performance criteria considered were
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sided assembly lines. maximizing the weighted line efficiency and minimizing
An ant colony optimization algorithm for the weighted smoothness index.
balancing two-sided assembly lines was presented by A binary fuzzy goal programming approach was
Simaria and Vilarinho (2009) [42]. Two-sided assembly presented by Kara et al. (2009) [48] for single model
lines are a special type of assembly lines in which straight and U-shaped assembly line balancing. 37
workers perform assembly tasks in both sides of the Assembly line balancing generally requires a set of
Ozcan and Toklu (2009) [52] works on Multiple- The use of Computer Numerical Control (CNC)
criteria decision-making in two-sided assembly line machines is a common way to add more flexibility or
balancing: A goal programming and a fuzzy goal reconfigurability to a machining line. Such machines are
programming model. They presented a mathematical highly automated and use computer programs to define
model, a pre-emptive goal programming model for the different tools to use for a specific part. Therefore
precise goals and a fuzzy goal programming model for they correspond to standard and interchangeable units
imprecise goals for two-sided assembly line balancing. in which a new program can be loaded to change the
The mathematical model minimizes the number of production.
matedstations as the primary objective and it mini- Ozcan (2010) [58] published their finding on
mizes the number of stations as a secondary objective balancing stochastic two-sided assembly lines: A
for a given cycle time. A work on MIP approach for chance-constrained, piecewise-linear, mixed integer
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balancing transfer line with complex industrial const- program and a simulated annealing algorithm. In this
raints was presented by Essafi et al. (2010) [53]. Accor- type of a production line, both left-side and right-side of
ding to them at least one CNC machine is to be installed the line are used in parallel. The problem of balancing
at each workstation. The objective was to assign a given twosided assembly lines with stochastic task times was
38 set of operations required for the machining of the part considered in this work. A chance-constrained, piece
to a sequence of workstations while minimizing the total wise linear, mixed integer program was proposed to
number of machines used. This problem was subject to model and solve the problem. A work on multi objective
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precedence, exclusion and inclusion constraints. constructive heuristics for the 1/3 variant of the time and
Toksari et al. (2010) [54] works on assembly space assembly line balancing problem: ACO and
line balancing problem with deterioration tasks and random greedy search was reported by China et al.
learning effect. In this simultaneous effects of learning (2010) [59]. Two new multi objective proposals based
and linear deterioration were introduced into assembly on ant colony optimization and random greedy search
line balancing problem. In many realistic settings, algorithms was presented to solve a classical industrial
although the actual task time of a task is modeled as an problem: time and space assembly line balancing.
increasing function of its starting time due to Some variants of these algorithms had been compared
deterioration effects the produced worker develops in order to find out the impact of different design
continuously by repeated the same or similar activities. configurations and the use of heuristic information.
The objective of problem was to minimize the station Yeh and Kao (2010) [60] reported on a new
number and a mixed nonlinear integer programming bidirectional heuristic for the assembly line balancing
model was developed. A research work on assembly problem. According to them, Assembly line balancing
Global Journal of Researches in Engineering ( G
line balancing to minimize balancing loss and system problem (ALBP) is one of the well-known NP-hard layout
loss was published by Roy and Khan (2010) [55]. planning problems for mass production systems.
Assembly Line production is one of the widely used Similarly, a work on simultaneous balancing and
basic principles in production system. The main aim scheduling of flexible mixed model assembly lines with
was to redefine the objective of the Assembly Line sequence-dependent setup times was published by
Balancing Problem and sequentially handle Balancing Ozturk et al. (2010) [61]. They have considered
Loss and System Loss. simultaneous balancing and scheduling of flexible mixed
Fan et al. (2010) [56] published their work on model assembly lines with sequence-dependent setup
balancing and simulating of assembly line with times. They have proposed alternate Mixed Integer
overlapped and stopped operation on the subject Programming and Constraint Programming
modeling and simulation of assembly line with formulations.
overlapped and stopped operation, builds mathematical Likewise, in the field of application of genetic
model for the assembly line both under certainty and algorithm the important works have been performed by
uncertainty environment. Taha (2011) [62] Akpinar and Bayhan (2011) [63] and
Essafi et al. (2010) [57] worked on balancing Chica et al. (2011) [64].
lines in CNC machines based on heuristic method of Ozbakir and Tapkan (2011) [65] published their
line balancing. The optimization of production systems work on bee colony intelligence in zone constrained two-
is an important stage for manufacturers to minimize sided assembly line balancing problem. In this study
costs and remain competitive. However, in the current two-sided assembly line balancing problem with zoning
economic context, with market volatility and fluctuation constraint was solved by bees algorithm so as to
in demand, industrials manufacturers need more flexible minimize the number of stations for a given cycle time.
production systems. Thus, new types of lines were Likewise, a work on bi-criteria assembly line balancing
created; i.e. flexible and reconfigurable transfer lines. by considering flexible operation times was presented
The flexibility or the recon figurability of a line is obtained by Hamta et al. (2011) [66].
through the use of special machines, a developed Kilincci (2011) [67] worked on firing sequences
control system for the line, a specific architecture, etc. backward algorithm for simple assembly line balancing
problem of type 1 and published their work on the same. Multi-objective optimization of a stochastic
The objective of simple assembly line balancing assembly line balancing: A hybrid simulated annealing
problem type-1 (SALBP-1) was to minimize the number algorithm was published by Cakir et al. (2011) [72]. This
of workstations on an assembly line for a given cycle work deals with multi-objective optimization of a single-
time. A new heuristic algorithm was presented to solve model stochastic assembly line balancing problem with
the problem. The presented algorithm makes an order parallel stations. The objectives were as follows: (1)
of firing sequence of transitions from Petri net model. minimization of the smoothness index and (2)
Task was assigned to a workstation using this order and minimization of the design cost. Ozbakira et al. (2011)
backward procedure. [73] works on Multiple-colony ant algorithm for parallel
A work was published by Chica et al. (2011) assembly line balancing problem. Assembly lines are
[68] which shows their work on different kinds of designed as flow oriented production systems which
preferences in a multi-objective ant algorithm for time perform operations on standardized products in a serial
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and space assembly line balancing on different Nissan manner. In this work, a novel multiple colony and algo
scenarios. The main focus of this was to study influence rithm was developed for balancing by objective parallel
of incorporating user preferences based on Nissan assembly lines. The proposed approach was extensively
automotive domain knowledge to guide the multi- tested on the benchmark problems and performance of
objective search process with two different aims. First, the approach is compared with existing algorithms. 39
to reduce the number of equally preferred assembly line Blum and Miralles (2011) [74] works on solving
compensate for the drawbacks of traditional robust garment factories and experimental design were used to
criteria. evaluate GGAs performance.
A genetic algorithm based approach for Rabbani et al. (2012) [82] works on mixed
simultaneously balancing and sequencing of mixed- model U-line balancing type-1 problem. In this a new
model U-lines with parallel workstations and zoning approach to balance a mixed model U-shaped
constraints was presented by Hamzadayi and Yildiz production system independent was developed for any
(2012) [78]. A Priority-Based Genetic Algorithm based product sequences. This approach was based on
method was presented for the simultaneously tackling of minimization of crossover workstations. In balancing
the mixed-model U-shape assembly line line mixed model assembly lines in U-shaped line layouts
balancing/model sequencing problems with parallel was more complicated than that of straight lines.
workstations and zoning constraints and allows the A model was developed in which minimizing the
Year 2013
decision maker to control the process to create parallel number of crossover workstations and maximizing the
workstations and to work in different scenarios. In this, line efficiency were considered at same time.
simulated annealing based fitness evaluation approach Mixed-model assembly line balancing in the
was developed to be able to make fitness function make-to-order and stochastic environment using multi-
40 calculations easily and effectively. objective evolutionary algorithms was stated by
Cheshmehgaz (2012) [79] worked on Manavizadeh et al. (2012) [83]. A multi-objective genetic
accumulated risk of body postures in assembly line algorithm (MOGA) was present to solve a mixed-model
D ) Volume XIII Issuev vII Version I
balancing problem and modeling through a multi-criteria assembly line problem (MMALBP), considering cycle
fuzzy-genetic algorithm. A novel model of assembly line time (CT) and the number of stations simultaneously. In
balancing problem was presented that incorporates this work, a mixed-model assembly line had been put
assembly worker postures into the balancing. Also a forth in a make-to-order (MTO) environment according
new criterion of posture diversity was defined and to the stochastic environment of production systems.
contributes to enhance the model. The proposed model Also a MOGA approach was presented to solve the
suggests configurations of assembly lines via the corresponding balancing problem and the decision
balancing and the assigned workers gets the maker was provided with the subsequent answers to
opportunities of changing their body postures, regularly. pick one based on the specific situation.
Mahto and Kumar (2012) [80] works on an Modeling and solving constrained two-sided
empirical investigation of assembly line balancing assembly line balancing problem via bee algorithms
techniques and optimized implementation approach for was presented by Tapkana et al. (2012) [84]. A fully
efficiency improvements. The concept of mass constrained two-sided assembly line balancing problem
Global Journal of Researches in Engineering ( G
production essentially involved the assembly of identical was addressed in this research work. A mathematical
or interchangeable parts of components into the final programming model was presented in order to describe
product at different stages and workstations. The the problem formally. Due to the problem complexity,
relative advantages and disadvantages of mass or flow two different swarm intelligence based search
production were a matter of concern for any mass algorithms are implemented to solve large-sized
production industry. How to design an assembly line instances. Bees algorithm and artificial bee colony
starting from the work breakdown structure to the final algorithm had been applied to the fully constrained two-
grouping of tasks at work stations had been discussed sided assembly line balancing problem so as to
in this work using two commonly used procedures minimize the number of workstations and to obtain a
namely the Kilbridge-Wester Heuristic approach and the balanced line.
Helgeson-Birnie Approach. Line Balancing was a Chutima and Chimklai (2012) [85] works on
classic, well-researched Operations Research multi-objective two-sided mixed-model assembly line
optimization problem of significant industrial importance. balancing using particle swarm optimisation with
The core objectives of this work was to optimize crew negative knowledge. Particle swarm optimisation (PSO)
size, system utilization, the probability of jobs being is an evolutionary metaheuristic inspired by the
completed within a certain time frame and system swarming behavior observed in flocks of birds. A PSO
design costs. These objectives were addressed algorithm was presented with negative knowledge
simultaneously, and the results obtained were (PSONK) to solve multi-objective two-sided mixed-
compared with those of single-objective approaches. model assembly line balancing problems. Instead of
A work on assembly line balancing in garment modelling the positions of particles in an absolute
industry was presented by Chen et al. (2012) [81]. A manner as in traditional PSO, PSONK employed the
grouping genetic algorithm (GGA) was developed for knowledge of the relative positions of different particles
ALBP of sewing lines with different labor skill levels. in generating new solutions.
GGA can allocate workload among machines as evenly Multi objective memetic algorithms for time and
as possible for different labor skill levels, so the mean space assembly line balancing were presented by Chica
absolute deviations can be minimized. Real data from et al. (2012) [86]. Three proposals of multi-objective
memetic algorithms were presented to solve a more assembly line balancing problem (ALBP) considered
realistic extension of a classical industrial problem: time where the operation times of tasks were unknown
and space assembly line balancing. These three variables and the only known information was the lower
proposals were, respectively, based on evolutionary and upper bounds for operation time of each task.
computation, ant colony optimization, and greedy Three objectives were simultaneously considered as
randomized search procedure. An efficient branch and follows: (1) minimizing the cycle time, (2) minimizing the
bound algorithm for assembly line balancing problem total equipment cost, and (3) minimizing the
with parallel multi-manned workstations was presented smoothness index. A new solution method was
by Kellegoz and Toklu (2012) [87]. Assembly lines with proposed which is based on the combination of particle
parallel multi-manned workstations and one of their swarm optimization (PSO) algorithm with variable
balancing problems were addressed, and a branch and neighborhood search (VNS) to solve the problem.
bound algorithm was proposed. The algorithm was A Simulated Annealing algorithm for a mixed
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composed of a branching scheme, some efficient model assembly U-line balancing type-I problem
dominance and feasibility criteria based on a problem- considering human efficiency and Just-In-Time
specific knowledge. A heuristic-based guidance for approach was presented by Manavizadeh et al. (2013)
enumeration process was included as an efficient [93]. This work deals with balancing a mixed-model U-
component of the algorithm as well. Battaia and Dolgui line in a Just-In-Time (JIT) production system. The 41
(2012) [88] works on reduction approaches for a research tries to reduce the number of stations via
of operations are related to the front part of the certain tasks. A heuristic procedure providing a
workpiece and others are related to the back part of the compromised between the objective function and the
workpiece, which in turn makes all tasks dependent on suggested stability measure was developed and
the position of the workpiece, (ii) some of the tasks must evaluated on benchmark data sets.
be executed on the same station and no other tasks A work on two-sided assembly lines balancing
should be assigned to this station due to technological with assignment restrictions was presented by Purnomo
restrictions, (iii) parallel stations are allowed to increase et al. (2013) [99]. Two-sided assembly line is a set of
the line efficiency at the required production rate and to sequential workstations where task operations can be
overcome the problem of assigning tasks with operation performed in two sides of the line. In this work a
times that exceed the cycle time. Initially, the problem mathematical model was proposed for two-sided
was formulated as a 01 integer programming model assembly line type II. The aim of the model was
Year 2013
and solved using CPLEX solver. Then, the effect of minimizing the cycle time for a given number of mated-
alternative work schedules such as multiple shifts and workstations and balancing the workstation
overtime on the expected labor cost of the line was simultaneously.
analyzed. Mozdgira et al. (2013) [100] published their work
42 A work on hybridizing ant colony optimization using the Taguchi method to optimize the differential
via genetic algorithm for mixed-model assembly line evolution algorithm parameters for minimizing the
balancing problem with sequence dependent setup workload smoothness index in simple assembly line
D ) Volume XIII Issuev vII Version I
times between tasks was presented by Sener et al. balancing. An assembly line is a flow-oriented
(2013) [97]. This work presented a new hybrid algorithm, production system in which the productive units
which executes ant colony optimization in combination performing the operations, referred to as stations, are
with genetic algorithm (ACO-GA), for type I mixed-model aligned in a serial manner. In this work the SALBP is
assembly line balancing problem (MMALBP-I) with some further classified into SALBP-1, SALBP-2, SALBP-E and
particular features of real world problems such as finally SALBP-F. In this work, a differential evolution
parallel workstations, zoning constraints and sequence algorithm was developed to minimize workload
dependent setup times between tasks. smoothness index in SALBP-2. Also, the algorithm
A work on stability measure for a generalized parameters were optimized using the Taguchi method.
assembly line balancing problem was published by
Gurevsky et al. (2013) [98]. A generalized formulation for IV. Summary OF Literature Survey
assembly line balancing problem (GALBP) was The summery research done by experts in the
considered, where several workplaces were associated
Global Journal of Researches in Engineering ( G
Year 2 013
26 Azar et al. (2006) Load balancing of temporary tasks
27 Scholl and Becker (2006) Simple assembly line balancing
28 McGovern and Gupta (2007) Disassembly line balancing
29 Agpak and Gokcen (2007) Stochastic line balancing 43
30 Boysen and Fliedner (2007) Assembly line balancing problem
machines
76 Bautista and Pereira (2011) Time and space constrained assembly line
balancing
77 Weida and Tianyuan (2011) Mixed model assembly line balancing based on
scenario planning
78 Hamzadayi and Yildiz (2012) Balancing and sequencing of mixed-model U-
lines with parallel workstations
79 Cheshmehgaz (2012) Body postures in assembly line balancing
80 Mahto and Kumar (2012) Assembly line balancing techniques
81 Chen et al. (2012) Assembly line balancing
82 Rabbani et al. (2012) Mixed model U-line balancing type-I
83 Manavizadeh et al. (2012) Mixed-model assembly line balancing
84 Tapkana et al. (2012) Two-sided assembly line balancing
Global Journal of Researches in Engineering ( G
Simple (SLAB)
Deterministic
(SMD)
General
(GALB)
Single Model
Simple (SLAB)
Stochastic
(SMS)
General
(GALB)
ALB Literature
Year 2 013
Simple (SLAB)
Deterministic
(SMD)
General
(GALB) 45
Multi Mixed
x Experimental results of algorithm integrated with the number of workstations and to obtain a balanced
Hoffmann heuristic shows the proposed procedure line.
are more efficient. x Genetic algorithm and iterative first-fit rule are used
x An ant colony optimization algorithm is proposed to to solve the problem and experiments shows finding
solve the assembly problem in which two ants work the best position over many workstations and the
simultaneously one at each side of the line to build a genetic algorithm provided more flexible task
balancing solution which verifies the precedence, assignment.
zoning, capacity, side and synchronism constraints
VI. Conclusion
of the assembly process.
x The single-model U-type assembly line balancing From the study of assembly line balancing it is
found that assembly lines are flow-line production
Year 2013
x A simulation prototype system is developed for This can be done by minimization of the number of
effective and correct assembly line balancing workstations and maximization of the production rate as
problem. studied in the literature survey.
x Two-sided assembly lines with stochastic task times It has been also observed that equipment costs, cycle
are considered for task time variation due to two- time, the correlation between task times and equipment
sided assembly lines with stochastic task times. costs and the flexibility ratio needs a great attention.
x New genetic algorithm is proposed to find the x A heuristic procedure for solving larger size of
optimum solutions within a limited number of problems can be designed.
iterations. x Paralleling of workstations and tasks may be
x A bi-criteria nonlinear integer programming model is studied to improve the line efficiency.
developed for minimizing the cycle time and x To select a single equipment to perform each task
minimizing the machine total costs. from a specified equipment set.
Global Journal of Researches in Engineering ( G
x Simulation tools such as Fact- Model, to modeling x Bee and ant colony algorithm to be adopted for
the production line and the works estimated are finding number of workstations.
used to reduce the line unbalancing causes and
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