An integrated bi-objective U-shaped assembly line balancing and parts feeding problem: optimization model and exact solu
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An integrated bi-objective U-shaped assembly line balancing and parts feeding problem: optimization model and exact solution method Ömer Faruk Yılmaz 1 Accepted: 6 November 2020/ # Springer Nature Switzerland AG 2020
Abstract
In this study, an integrated bi-objective objective U-shaped assembly line balancing and parts feeding problem is explored by considering the heterogeneity inherent of workers. An optimization model is developed to formulate the addressed problem. Since the problem includes two different objectives, namely the minimizing the operational cost and maximum workload imbalance, the Pareto-optimal solutions are found by employing the second version of the augmented ε-constrained (AUGMECON2) method. To investigate the impact of qualification of workers on the system performance, a set of scenarios is constructed based on the worker skill levels. Each scenario is determined based on the nature of the worker pool in which workers are assigned to the stations. The optimization model and implemented method are validated through data taken from water-meter and elevator producers. The computational results reveal that the scenarios have a great impact on system performance. In particular, it is revealed that as the skill levels of workers increases, the quality of the Pareto-optimal solutions increase by up to 30% in terms of the comparison metrics. Therefore, an order release mechanism and worker training activities are suggested to be performed to enhance system performance. Keywords U-shaped assembly line balancing problem . Parts feeding problem . Bi-objective optimization model . AUGMECON2 method
1 Introduction Nowadays, with the current trend to high product assortment and small-volume manufacturing, the companies optimize their production system to become resilient. In this manner, the manufacturers have converted their traditional systems into a more robust system so as to * Ömer Faruk Yılmaz [email protected]
1
Department of Industrial Engineering, Karadeniz Technical University, 61080 Trabzon, Turkey
Yılmaz Ö.F.
satisfy customers’ demand within a shorter manufacturing lead time. Assembly lines are effective in a way that large units can be produced shorter lead time by applying the onepiece flow principle. On one hand, utilizing traditional assembly lines provides many benefits, such as economy of scale and competitiveness. On the other hand, it leads to some disadvantages that can be eliminated, such as great shop-floor requirements, preventing group working, and skill enhancement [1]. Besides, it cannot fully provide some other benefits, such as visibility, motivation, and communication. In order to utilize the advantages of assembly lines, traditional assembly lines have been converted to U-shaped lines following the lean manufacturing principles [2, 3]. After the U-shaped assembly line is designed, it needs to be balanced accordingly [4]. Assembly line balancing requires assigning the tasks to the stations in such a way that all tasks are assigned under necessary constraints,
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