Uğur Özcan

Multiple-criteria decision-making in two-sided assembly line balancing: A goal programming and a fuzzy goal programming models

Two-sided assembly lines are especially used at the assembly of large-sized products, such as trucks and buses. In this type of a production line, both sides of the line are used in parallel. In practice, it may be necessary to optimize more than one conflicting objectives simultaneously to obtain effective and realistic solutions. This paper presents a mathematical model, a pre-emptive goal programming model for precise goals and a fuzzy goal programming model for imprecise goals for two-sided assembly line balancing. The mathematical model minimizes the number of mated-stations as the primary objective and it minimizes the number of stations as a secondary objective for a given cycle time. The zoning constraints are also considered in this model, and a set of test problems taken from literature is solved. The proposed goal programming models are the first multiple-criteria decision-making approaches for two-sided assembly line balancing problem with multiple objectives. The number of mated-stations, cycle time and the number of tasks assigned per station are considered as goals. An example problem is solved and a computational study is conducted to illustrate the flexibility and the efficiency of the proposed goal programming models. Based on the decision makers preferences, the proposed models are capable of improving the value of goals.

Balancing of mixed-model two-sided assembly lines

This paper presents a new mathematical model and a simulated annealing algorithm for the mixed-model two-sided assembly line balancing problem. The proposed mathematical model minimizes the number of mated-stations (i.e., the line length) as the primary objective and minimizes the number of stations (i.e., the number of operators) as a secondary objective for a given cycle time. In the proposed simulated annealing algorithm, two performance criteria are considered simultaneously: maximizing the weighted line efficiency and minimizing the weighted smoothness index. The proposed approach is illustrated with an example problem, and its performance is tested on a set of test problems. The experimental results show that the proposed approach performs well.

Balancing stochastic two-sided assembly lines: A chance-constrained, piecewise-linear, mixed integer program and a simulated annealing algorithm

Two-sided assembly lines are often designed to produce large-sized products, such as automobiles, trucks and buses. In this type of a production line, both left-side and right-side of the line are used in parallel. In all studies on two-sided assembly lines, the task times are assumed to be deterministic. However, in real life applications, especially in manual assembly lines, the tasks may have varying execution times defined as a probability distribution. The task time variation may result from machine breakdowns, loss of motivation, lack of training, non-qualified operators, complex tasks, environment, etc. In this paper, the problem of balancing two-sided assembly lines with stochastic task times (STALBP) is considered. A chance-constrained, piecewise-linear, mixed integer program (CPMIP) is proposed to model and solve the problem. As a solution approach a simulated annealing (SA) algorithm is proposed. To assess the effectiveness of CPMIP and SA algorithm, a set of test problems are solved. Finally, computational results indicating the effectiveness of CPMIP and SA algorithm are reported.

Balancing and sequencing mixed-model just-in-time U-lines with multiple objectives

This study deals with the mixed-model U-lines utilized in just-in-time (JIT) production systems. Successful implementations of mixed-model U-lines requires solutions to two important problems called line balancing and model sequencing. In terms of some balance-dependent performance measures the effectiveness of a mixed-model U-line can be increased by solving line balancing and model sequencing problems simultaneously. However, this may lead to inefficient values of sequence-dependent performance measures. Hence, increasing the effectiveness of a mixed-model U-line requires balancing and sequencing problems that be dealt with multiple objectives. Balancing and sequencing mixed-model U-lines with multiple objectives has not been considered in the literature to date. In this study, a multi-objective approach for balancing and sequencing mixed-model U-lines to simultaneously minimize the absolute deviations of workloads across workstations, part usage rate, and cost of setups is presented. To increase the performance of the proposed algorithm, a newly developed neighbourhood generation method is also employed. Since the performance measures considered in the study are conflicting with each other, the proposed algorithm suggests much flexibility and more realistic results to decision makers. Solution methodology is illustrated using an example and a two-stage comprehensive experimental study is conducted to determine the effective values of algorithm parameters and investigate the relationships between performance measures. Results show that the proposed approach is more realistic than the limited number of existing methodologies. The proposed approach is also extended to consider the stochastic completion times of tasks.

A genetic algorithm for the stochastic mixed-model U-line balancing and sequencing problem

Mixed-model assembly lines are widely used to improve the flexibility to adapt to the changes in market demand, and U-lines have become popular in recent years as an important component of just-in-time production systems. As a consequence of adaptation of just-in-time production principles into the manufacturing environment, mixed-model production is performed on U-lines. This type of a production line is called a mixed-model U-line. In mixed-model U-lines, there are two interrelated problems called line balancing and model sequencing. In real life applications, especially in manual assembly lines, the tasks may have varying execution times defined as a probability distribution. In this paper, the mixed-model U-line balancing and sequencing problem with stochastic task times is considered. For this purpose, a genetic algorithm is developed to solve the problem. To assess the effectiveness of the proposed algorithm, a computational study is conducted for both deterministic and stochastic versions of the problem.

Balancing two-sided assembly lines with sequence-dependent setup times

Two-sided assembly lines are often designed to produce large-sized products, such as automobiles, trucks and buses. In this type of production line, both left-side and right-side of the line are used in parallel. In all studies on two-sided assembly lines, sequence-dependent setup times have not yet been considered. However, in real life applications, setups may exist between tasks. Performing a task directly before another task may influence the latter task inside the same station, because a setup for performing the latter task may be required. Furthermore, if a task is assigned to a station as the last one, then it may cause a setup for performing the first task assigned to that station since the tasks are performed cyclically. In this paper, the problem of balancing two-sided assembly lines with setups (TALBPS) is considered. A mixed integer program (MIP) is proposed to model and solve the problem. The proposed MIP minimises the number of mated-stations (i.e., the line length) as the primary objective and it minimises the number of stations (i.e., the number of operators) as a secondary objective for a given cycle time. A heuristic approach (2-COMSOAL/S) for especially solving large-size problems based on COMSOAL (computer method of sequencing operations for assembly lines) method is also presented. An illustrative example problem is solved using 2-COMSOAL/S. To assess the effectiveness of MIP and 2-COMSOAL/S, a set of test problems are solved. The computational results show that 2-COMSOAL/S is very effective for the problem.

Balancing and sequencing of parallel mixed-model assembly lines

In this paper, a simulated annealing approach is developed for the parallel mixed-model assembly line balancing and model sequencing (PMMAL/BS) problem which is an extension of the parallel assembly line balancing (PALB) problem introduced by Gökçen et al. (2006). In PALB, the aim is to balance more than one assembly line together. Balancing of the lines simultaneously with a common resource is very important in terms of resource minimisation. The proposed approach maximises the line efficiency and distributes the workloads smoothly across stations. The proposed approach is illustrated with two numerical examples and its performance is tested on a set of test problems. The computational results show that the proposed approach is very effective for PMMAL/BS.

Balancing parallel two-sided assembly lines

Two-sided assembly lines are usually designed to produce large-sized products such as automobiles, trucks and buses. In this type of production line, both left-side and right-side of the line are used. In parallel assembly lines, one or more product types are produced on two or more assembly lines located in parallel to each other. Both production lines have several serious practical advantages. For this purpose, in this paper, two or more two-sided assembly lines located in parallel to each other are considered and a tabu search algorithm which combines the advantages of both types of production lines is developed. To assess the effectiveness of the proposed algorithm, a set of test problems are solved. The proposed algorithm is illustrated with two examples, and some computational properties of the algorithm are given.

A modified particle swarm optimization algorithm to mixed-model two-sided assembly line balancing

In this paper, a new modified particle swarm optimization algorithm with negative knowledge is proposed to solve the mixed-model two-sided assembly line balancing problem. The proposed approach includes new procedures such as generation procedure which is based on combined selection mechanism and decoding procedure. These new procedures enhance the solution capability of the algorithm while enabling it to search at different points of the solution space, efficiently. Performance of the proposed approach is tested on a set of test problem. The experimental results show that the proposed approach can be acquired distinguished results than the existing solution approaches.

A fuzzy goal programming model for the simple U-line balancing problem with multiple objectives

A fuzzy goal programming model for the simple U-line balancing (SULB) problem with multiple objectives is presented. In real life applications of the SULB problem with multiple objectives, it is difficult for the decision-maker(s) to determine the goal value of each objective precisely as the goal values are imprecise, vague, or uncertain. Therefore a fuzzy goal programming model is developed for this purpose. The proposed model is the first fuzzy multi-objective decision-making approach to the SULB problem with multiple objectives which aims at simultaneously optimizing several conflicting goals. The proposed model is illustrated using an example. A computational study is conducted by solving a large number of test problems to investigate the relationship between the fuzzy goals and to compare them with the goal programming model proposed by Gökçen and Ağpak (Gökçen, H. and Ağpak, K., European Journal of Operational Research, 171, 577–585, 2006). The results of the computational study show that the proposed model is more realistic than the existing models for the SULB problem with multiple objectives and also provides increased flexibility for the decision-maker(s) to determine different alternatives.