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MULTI-OBJECTIVE GENETIC ALGORITHM FOR THE ASSEMBLY LINE WORKER ASSIGNMENT AND BALANCING PROBLEM: A CASE STUDY IN THE AUTOMOTIVE SUPPLY INDUSTRY

Year 2024, Issue: 056, 3 - 22, 31.03.2024
https://doi.org/10.59313/jsr-a.1354104

Abstract

The primary challenge in assembly line design is the need for more appropriately allocating tasks and workers to workstations. This study addresses the problem of line balancing and worker assignments, considering the performance disparities among workers during the line balancing process. In the relevant literature, this problem is known as the Assembly Line Worker Assignment and Balancing (ALWAB) problem. This research examines a multi-objective ALWAB Type-2 problem, simultaneously evaluating cycle time and squared load assignment objectives. The study is conducted based on a real-life scenario in a sub-industry automotive industry that manufactures cable equipment. To solve this problem, a multi-objective genetic algorithm approach is proposed. Recognising that the selection of parameter values will influence the algorithm’s performance, parameter calibration has been performed. A full factorial experimental design and the irace method have been utilised for this purpose. The results are compared with those using parameter values utilised for similar problems in the literature. Furthermore, a sensitivity analysis has been carried out to examine the impact of various relative weight values of the objectives on the result. The results indicate that the experimental design generally yields superior results compared to other methods.

References

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Year 2024, Issue: 056, 3 - 22, 31.03.2024
https://doi.org/10.59313/jsr-a.1354104

Abstract

References

  • [1] Kobu, B., Üretim yönetimi (17. baskı). İstanbul: Beta Yayınevi, 2014
  • [2] Boysen, N., Fliedner, M. and Scholl, A.,A classification of assembly line balancing problems. European journal of operational research, 183(2), 674-693. URL: https://doi.org/10.1016/j.ejor.2006.10.010, 2007.
  • [3] Okyay, Y. R.,Solving assembly line balancing problem with positional constraints and worker assignments using mathematical programming and heuristic solution approaches. Yayımlanmamış Yüksek Lisans Tezi, Dokuz Eylül Üniversitesi Fen Bilimleri Enstitüsü, İzmir, 2018
  • [4] Zacharia, P. T. and Nearchou, A. C., A population-based algorithm for the bi-objective assembly line worker assignment and balancing problem. Engineering Applications of Artificial Intelligence, 49, 1-9. URL: https://doi.org/10.1016/j.engappai.2015.11.007, 2016
  • [5] Çengil, M.F., Heuristic approaches for assembly line balancing and competent worker asignment problem (ALWABP). Yayımlanmamış Yüksek Lisans Tezi, Özyeğin Universitesi Fen Bilimleri Enstitüsü, İstanbul, 2018
  • [6] Becker, C. and Scholl, A.,A survey on problems and methods in generalized assembly line balancing. European Journal of Operational Research, 168(3), 694-715. URL: https://doi.org/10.1016/j.ejor.2004.07.023,2006
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  • [13] Arıkan, M., İş yükü dengelemeli ikinci tip basit montaj hattı dengeleme problemi için bir tabu arama algoritması. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi, 32(4), 1169-1179. URL: https://doi.org/10.17341/gazimmfd.369529,2017
  • [14] Delice, Y., Aydoğan, E. K., Söylemez, I. and Özcan, U., An ant colony optimisation algorithm for balancing two-sided U-type assembly lines with sequence-dependent set-up times. Computer Science, Sādhanā, 43, 1-15. URL: https://doi.org/10.1007/s12046-018-0969-9,2018
  • [15] Süer, G.A., Sinaki, R.Y. and Sadeghi, A., A hierarchical hybrid heuristic optimization approach for multi-product assembly line design problem. Procedia Manufacturing, 39, 1067–1075. URL: https://doi.org/10.1016/j.promfg.2020.01.368,2019
  • [16] Karsu, Ö. and Azizoğlu, M., An exact algorithm for the minimum squared load assignment problem. Computers & Operations Research, 106, 76-90. URL: https://doi.org/10.1016/j.cor.2019.02.011,2019b
  • [17] Meng, K., Tang, Q., Zhang, Z. and Qian, X., An improved lexicographical whale optimization algorithm for the type-II assembly line balancing problem considering preventive maintenance scenarios. IEEE Access, 8, 30421-30435. URL: 2020
  • [18] Erten, K., Darboğaz genelleştirilmiş atama problemi için bir çözüm yaklaşımı. Yayımlanmamış Yüksek Lisans Tezi, Eskişehir Osmangazi Üniversitesi Fen Bilimleri Enstitüsü, Eskişehir, 2021
  • [19] Tang, Q., Meng, K., Cheng, L. and Zhang, Z., An improved multi-objective multifactorial evolutionary algorithm for assembly line balancing problem considering regular production and preventive maintenance scenarios. Swarm and Evolutionary Computation, 68(3), 101021. URL: https://doi.org/10.1016/j.swevo.2021.101021, 2022
  • [20] Hashemi-Petroodi, S. E., Thevenin, S., Kovalev, S. and Dolgui, A., Model-dependent task assignment in multi-manned mixed model assembly lines with moving workers. Omega, 113(12), 1-46. URL: https://doi.org/10.1016/j.omega.2022.102688,2 021
  • [21] Yin, T., Zhang Z., Zhang, Y., Wu, T. & Liang, W., Mixed-integer programming model and hybrid driving algorithm for multi-product partial disassembly line balancing problem with multi-robot workstations. Robotics and Computer-Integrated Manufacturing, 73, 102251. URL: https://doi.org/10.1016/j.rcim.2021.102251, 2022
  • [22] Meng, K., Thang, Q., Cheng, L. and Zhang, Z., Mixed-model assembly line balancing problem considering preventive maintenance scenarios: MILP model and cooperative co-evolutionary algorithm. Applied Soft Computing, 127, 109341. URL: https://doi.org/10.1016/j.asoc.2022.109341,2022
  • [23] Zhao, L., Tang Q. and Zhang, Z., An improved preference-based variable neighborhood search algorithm with ar-dominance for assembly line balancing considering preventive maintenance scenarios. Engineering Applications of Artificial Intelligence, 109, 104593. URL: https://doi.org/10.1016/j.engappai.2021.104593, 2022
  • [24] Aryanezhad, M.B., Deljoo, V. and Mirzapour Al-e-hashem S.M.J., Dynamic cell formation and the worker assignment problem: a new model. The International Journal of Advanced Manufacturing Technology, 41(3), 329-342. URL: https://doi.org/10.1007/s00170-008-1479-4, 2009
  • [25] Blum, C. and Miralles, C., On solving the assembly line worker assignment and balancing problem via beam search. Computers & Operations Research, 38(1), 328-339. URL: https://doi.org/10.1016/j.cor.2010.05.008, 2011
  • [26] Sungur, B. and Yavuz, Y., Assembly line balancing with hierarchical worker assignment. Journal of Manufacturing Systems, 37(1), 290-298. URL: https://doi.org/10.1016/j.jmsy.2014.08.004, 2014
  • [27] Borba, L. and Ritt, M., A heuristic and a branch-and-bound algorithm for the assembly line worker assignment and balancing problem. Computers & Operations Research, 45, 87-96. URL: https://doi.org/10.1016/j.cor.2013.12.002, 2014
  • [28] Vilà, M. and Pereira, J., A branch-and-bound algorithm for assembly line worker assignment and balancing problems. Computers & Operations Research, 44, 105-114. URL: https://doi.org/10.1016/j.cor.2013.10.016 , 2014
  • [29] Ritt, M., Costa, A.M. and Miralles C., The assembly line worker assignment and balancing problem with stochastic worker availability. International Journal of Production Research, 54(3), 907-922. URL: https://doi.org/10.1080/00207543.2015.1108534, 2015
  • [30] Polat, O., Kalayci, C.B., Mutlu, Ö. and Gupta, S. A two-phase variable neighbourhood search algorithm for assembly line worker assignment and balancing problem type-II: An industrial case study. International Journal of Production Research, 54(3), 722-741. URL: https://doi.org/10.1080/00207543.2015.1055344 , 2016
  • [31] Janardhanan, M.N., Li, Z. and Nielsen, P., Model and migrating birds optimization algorithm for two-sided assembly line worker assignment and balancing problem. Soft Computing, 23(21), 11263-11276. URL: https://doi.org/10.1007/s00500-018-03684-8, 2019
  • [32] Yılmaz, H. and Demir, Y., A new mathematical model for assembly line worker assignment and balancing. Journal of the Institute of Science and Technology, 9(4), 2002-2008. URL: https://doi.org/10.21597/jist.579958, 2019
  • [33] Janardhanan, M.N., Li, Z., Nielsen, P. and Tang, Q., Artificial bee colony algorithms for two-sided assembly line worker assignment and balancing problem. In Distributed Computing and Artificial Intelligence, 14th International Conference, Advances in Intelligent Systems and Computing 620, Springer, Cham. URL: https://doi.org/10.1007/978-3-319-62410-5_2, 2018
  • [34] Topaloğlu, Yıldız, Ş., Yıldız, G. & Cin, E., Bir elektronik firmasındaki işçi atamalı montaj hattı dengeleme problemine matematiksel programlama ve benzetim modelleme tabanlı bir çözüm yaklaşımı. Afyon Kocatepe Üniversitesi İktisadi ve İdari Bilimler Fakültesi Dergisi, 22(1), 57-73. URL: https://doi.org/10.33707/akuiibfd.645402, 2020
  • [35] Zhang, Z., Tang, Q., Ruiz, R. and Zhang, L., Ergonomic risk and cycle time minimization for the U-shaped worker assignment assembly line balancing problem: A multi-objective approach. Computers and Operations Research, 118(2), 104905. URL: https://doi.org/10.1016/j.cor.2020.104905, 2020
  • [36] Karas, A. and Ozcelik, F., Assembly line worker assignment and rebalancing problem: A mathematical model and an artificial bee colony algorithm. Computers & Industrial Engineering, 156, 107195. URL: https://doi.org/10.1016/j.cie.2021.107195, 2021
  • [37] Campana, N.P., lori, M. and Moreira, C.O.,Mathematical models and heuristic methods for the assembly line balancing problem with hierarchical worker assignment. International Journal of Production Research, 60(7), 2193-2211. URL: https://doi.org/10.1080/00207543.2021.1884767, 2021
  • [38] Gräßler, I., Roeasmann, D., Cappelo, C. and Steffen, E. , Skill-based worker assignment in a manual assembly line. Procedia CIRP, 100, 433-438. URL: https://doi.org/10.1016/j.procir.2021.05.100, 2021
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There are 54 citations in total.

Details

Primary Language English
Subjects Industrial Engineering
Journal Section Research Articles
Authors

Gözde Kurada 0000-0003-0757-3269

Derya Deliktaş 0000-0003-2676-1628

Publication Date March 31, 2024
Submission Date September 1, 2023
Published in Issue Year 2024 Issue: 056

Cite

IEEE G. Kurada and D. Deliktaş, “MULTI-OBJECTIVE GENETIC ALGORITHM FOR THE ASSEMBLY LINE WORKER ASSIGNMENT AND BALANCING PROBLEM: A CASE STUDY IN THE AUTOMOTIVE SUPPLY INDUSTRY”, JSR-A, no. 056, pp. 3–22, March 2024, doi: 10.59313/jsr-a.1354104.