Erdal Erel

A survey of the assembly line balancing procedures

The assembly line balancing problem consists of assigning tasks to an ordered sequence of stations such that the precedence relations among the tasks are satisfied and some performance measure is optimized. Due to the complexity of the problem, heuristic procedures appear to be more promising than the optimum-seeking algorithms. For the single-model, deterministic version, there are numerous exact and heuristic algorithms developed, while for the other more complex but more realistic versions, the research published consists mainly of heuristic procedures. In this paper, the heuristic procedures are critically examined and summarized in sufficient detail to provide a state-of-the-art survey. An evaluation of the procedures and some further research topics have also been presented.

Multicriteria inventory classification using a genetic algorithm

One of the application areas of genetic algorithms is parameter optimization. This paper addresses the problem of optimizing a set of parameters that represent the weights of criteria, where the sum of all weights is 1. A chromosome represents the values of the weights, possibly along with some cut-off points. A new crossover operation, called continuous uniform crossover, is proposed, such that it produces valid chromosomes given that the parent chromosomes are valid. The new crossover technique is applied to the problem of multicriteria inventory classification. The results are compared with the classical inventory classification technique using the Analytical Hierarchy Process.

Assembly line balancing using genetic algorithms

Assembly Line Balancing (ALB) is one of the important problems of production/operations management area. As small improvements in the performance of the system can lead to significant monetary consequences, it is of utmost importance to develop practical solution procedures that yield high-quality design decisions with minimal computational requirements. Due to the NP-hard nature of the ALB problem, heuristics are generally used to solve real life problems. In this paper, we propose an efficient heuristic to solve the deterministic and single-model ALB problem. The proposed heuristic is a Genetic Algorithm (GA) with a special chromosome structure that is partitioned dynamically through the evolution process. Elitism is also implemented in the model by using some concepts of Simulated Annealing (SA). In this context, the proposed approach can be viewed as a unified framework which combines several new concepts of AI in the algorithmic design. Our computational experiments with the proposed algorithm indicate that it outperforms the existing heuristics on several test problems.

A goal programming approach to mixed-model assembly line balancing problem

Abstract In this paper, a binary goal programming model for the mixed-model assembly line balancing (ALB) problem is developed. The model is based on the concepts developed by Patterson and Albracht [1] and the model of Deckro and Rangachari [2] developed for the single-model ALB problem. The proposed model provides a considerable amount of flexibility to the decision maker since several conflicting goals can be simultaneously considered.

Balancing of U-type assembly systems using simulated annealing

The paper presents a new simulated annealing (SA)-based algorithm for the assembly line-balancing problem with a U-type configuration. The proposed algorithm employs an intelligent mechanism to search a large solution space. U-type assembly systems are becoming increasingly popular in todays modern production environments since they are more general than the traditional assembly systems. In these systems, tasks are to be allocated into stations by moving forward and backward through the precedence diagram in contrast to a typical forward move in the traditional assembly systems. The performance of the algorithm is measured by solving a large number of benchmark problems available in the literature. The results of the computational experiments indicate that the proposed SA-based algorithm performs quite effectively. It also yields the optimal solution for most problem instances. Future research directions and a comprehensive bibliography are also provided here.

Shortest-route formulation of mixed-model assembly line balancing problem

A shortest-route formulation of the mixed-model assembly line balancing problem is presented. Common tasks across models are assumed to exist and these tasks are performed in the same stations. The formulation is based on an algorithm which solves the single-model version of the problem. The mixed-model system is transformed into a single-model system with a combined precedence diagram. The model is capable of considering any constraint that can be expressed as a function of task assignments.

Binary integer formulation for mixed-model assembly line balancing problem

The assembly line balancing problem has been a focus of interest to the academicians of production/operations management for the last 40 years. Although there are numerous studies published on the various aspects of the problem, the number of studies on mixed-model assembly lines are relatively small. In this paper, a binary integer programming model for the mixed-model assembly line balancing problem is developed and some computational properties of the model are given.

Two exact formulations for disassembly line balancing problems with task precedence diagram construction using an AND/OR graph

In this paper, the disassembly line balancing problem, which involves determining a line design in which used products are completely disassembled to obtain useable components in a cost-effective manner, is studied. Because of the growing demand for a cleaner environment, this problem has become an important issue in reverse manufacturing. In this study, two exact formulations are developed that utilize an AND/OR Graph (AOG) as the main input to ensure the feasibility of the precedence relations among the tasks. It is also shown that traditional task precedence diagrams can be derived from the AOG of a given product structure. This procedure leads to considerably better solutions of the traditional assembly line balancing problems; it may alter the approach taken by previous researchers in this area.

A methodology for solving single-model, stochastic assembly line balancing problem

In this paper, a methodology is developed to solve the single-model, stochastic assembly line balancing problem for the objective of minimizing the total labor cost and the expected incompletion cost arising from tasks not completed within the prescribed cycle time. The methodology is based on determining an initial DP based solution and its improvement using a branch-and-bound procedure which uses an approximate solution instead of a lower bound for fathoming nodes. Detailed experimentation shows the superiority of this method over the most promising one from the literature.

Stochastic assembly line balancing using beam search

This paper presents a beam search-based method for the stochastic assembly line balancing problem in U-lines. The proposed method minimizes total expected cost comprised of total labour cost and total expected incompletion cost. A beam search is an approximate branch and bound method that operates on a search tree. Even though beam search has been used in various problem domains, this is the first application to the assembly line balancing problem. The performance of the proposed method is measured on various test problems. The results of the computational experiments indicate that the average performance of the proposed method is better than the best-known heuristic in the literature for the traditional straight-line problem. Since the proposed method is the first heuristic for the stochastic U-type problem with the total expected cost criterion, we only report its results on the benchmark problems. Future research directions and the related bibliography are also provided in the paper.