Assembly line balancing is a classical problem that has been widely studied in the literature. Description of the precedence graphs pdf description of the file format pdf salbp data sets zip file, provided by armin scholl references. The traditional line or straight line assembly line balancing problem considers a production line in which stations are arranged consecutively in a line. Marcel dekker, inc dave sly, a practical approach to solving multiobjective line balancing problem retrieved from. A multiobjective genetic algorithm for solving assembly. Line balancing techniques to improve productivity using work. Abstract line balancing is an effective tool to improve the throughput of assembly line while reducing nonvalueadded activities, cycle time. Also, the assembly line needs to be designed effectively and tasks needs to be distributed among workers, machines and work stations ensuring that every line segments. A study on line balancing in assembly line at automotive component manufacturer. Assembly line balancing is a production strategy that sets an intended rate of production to produce a particular product within a particular time frame. The problem seeks an efficient assignment of tasks to workstations in an assembly line subject to operational constraints.
Assign tasks to first workstation, using rules and staying within cycle time. Pdf the uline assembly line balancing problem researchgate. Sep 30, 20 university master student assembly line balancing precedence diagram cycle time work station duration. The assembly line balancing problem albp is a classic problem from literature, firstly approached by salveson 1955 in the article the assembly line balancing problem. Assembly line balancing problems can be classified by the type of problem 8,9, as shown in figure 1 10, 11. This study aims to improve the productivity and line efficiency also to recommend improvement activities based on the line balancing and analysis done in the simulation model. A genetic algorithm approach for the type ii assembly line. If the work elements can be grouped so that all the station times are exactly equal, we have perfect balance on the line and we can expect the production to. University master student assembly line balancing precedence diagram cycle time work station duration. Feasible solutions depend on work recently presented on integer solutions to linearprogramming problems. Assembly line balancing to improve productivity using work. Habitually, such relations are represented by a predetermined precedence graph. One and twosided assembly line balancing problems with real. Line balancing, line balancing operations management.
On the complexity of assembly line balancing problems. Problem two subproblems need to be solved simultaneously. Vila and pereira 20 solved worker assignment and albp by an exact enumeration algorithm. In this study, an approach di erent from traditional methods of assembly line balancing systems 15 and methods, such as the use of manmachine systems 6, is presented. However, a products assembly process may admit, for one or more of its parts. A constraint slows the process down and results if waiting for downstream operations and excess capacity results in waiting and absorption of fixed costs. Assembly line balancing problem with reduced number of. In general, the decision problem, so called assembly line balancing problem, is to find how these tasks are assigned to workstations, so that the predetermined goal is achieved. The assembly line balancing problems are classified into eight types based on three parameters, viz. As yet, the computation involved for a practical problem would be quite large. Depending upon the size of the duality gap, this lower bound might prove useful in a branchandbound algorithm for obtaining the optimal solution of the assembly line balancing problem. First, we study the onesided assembly line balancing problem albp with a limited number of machine types per workstation. In this study, we consider balancing problems of one and twosided assembly lines with realworld constraints like task or machine incompatibilities.
Benchmark data sets by scholl 1993 assembly line balancing. Since monden brought 4 ulines to the attention of research community, the first. Heuristics matanachai and yano considered the mixed10 model assembly line balancing problem with the objective of reducing work overload as well as maintaining reasonable workload balance among the workstations. Minimization of the number of workstations and maximization of the production rate are the most common goals studied in the assembly line balancing literature. This video has been prepared to assist my students at indiana university of pennsylvania iup, located in. Research in genetic algorithm ga and gga is then discussed. The problem is complicated by the relationships among tasks imposed by product design and process technologies. Review articles 7 cycle time as well as a line balance such that a capacity or even costoriented objective is optimized cf. In fact, assembly line can be a determinant in measuring the efficiency in the production operation of automotive manufacturer. Modified product layout and assembly line balancing example.
Utype and twosided assembly lines are two types of design having advantages over traditional straight assembly lines. Assembly line had evolved several times since the introduction of the first assembly line. A multiobjective genetic algorithm for solving assembly line. The performance criteria considered are the number of workstations, the line efficiency, the smoothness index before trade and transfer, and the smoothness index after trade and transfer. Since introduction of assembly lines by henry ford, line balancing has been an optimisation problem of important industrial importance. A classification of assembly line balancing problems. An analytical approach for single and mixedmodel assembly. Arranging stations in a sequence line for the product to move from one station to the next until its completion at the end of the line.
May 27, 2014 the assembly line balancing problems are classified into eight types based on three parameters, viz. Line balancing means balancing the line, for example balancing the production line or an assembly line. Mixedmodel ushaped assembly line balancing problems. Line balancing line balancing is levelling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. The assembly line balancing problem albp aims at assigning assembly operations to a set of workstations to optimize some performance measures, while satisfying technological, operational and organizational constraints benzer et al. Assemblyline balancing by linear programming operations. Heuristics for solving a multimodel robotic assembly line.
The simple assembly line balancing problem is an assembly line in the production of. A comparative evaluation of heuristic line balancing techniques. A study on line balancing in assembly line at automotive. A survey on problems and methods in generalized assembly. A new approach based on queuing theory for solving the. Line balancing techniques to improve productivity using. Maintaining and operating one is often quite costly, as well. Therefore, to efficiently solve the alternative subgraphs assembly line balancing. Assembly line balancing is the problem of assigning operations to workstations along an assembly line, in such a way that the assignment be best in some sense.
Since introduction of assembly lines by henry ford, linebalancing has been an optimisation problem of important industrial importance. Linearprogramming solutions to the assembly line balancing problem are offered in two forms. Suppose there are three machines work stations a, b and c, which can process 5, 10 and 15 pieces per unit time respectively and the pieces flow from a to b to c precedence constraint. This paper considers heuristics which can be helpful in reducing a workstations number in assembly line balancing problem. A survey on problems and methods in generalized assembly line.
This project mainly focuses on improving overall efficiency of single model assembly line by reducing the bottleneck activities, cycle time and distribution of work load at each work station by line. However, the problem is more difficult than in the singlemodel case, because the station. Line balancing is the assignment of work elements to stations in a line. One and twosided assembly line balancing problems with. Manufacturing a product on an assembly line requires partitioning the total amount of work into a set of elementary operations named tasks v 1, n. An example of line balancing assigning tasks to stations a precedence diagram is a lot like a process flow diagram.
The classic assembly line balancing problem basically consists in assigning a set of tasks to a group of workstations while maintaining the tasks precedence relations. Assembly line plays a critical role in enabling a factory to deliver on time and at the right quantity and quality. The line balancing problem is to arrange the individual processing and assembly tasks at the workstations so that the total time required at each workstation is approximately the same. Pdf an assembly line balancing problem automotive cables. The time and space assembly line balancing problem. The assembly line balancing problem aims at assigning assembly operations to a set of workstations in order to optimize some performance measures, while satisfying technological, operational, and. Assembly line balancing problem assembly line balancing is the problem of assigning various tasks to workstations, while optimizing one or more objectives without violating any restrictions imposed on the line. Line balancing is the problem of assigning operation to workstation along an assembly line, in such a way that assignment is optimal in some sense. Mixedmodel ushaped assembly line balancing problems with. This project main purpose is to assist in making an assembly.
An assembly line balancing problem automotive cables. In this study, an approach di erent from traditional methods of assembly line balancing systems 15 and methods, such as the use of man. Once the root cause was found, the corrective and improvement action such as redesign the. Repeat for following workstations until all tasks are assigned. Introduction the manufacturing assembly line was first intr oduced by henry ford in the early 1900 s. Pdf the assembly line balancing problem albp consists of assigning tasks to an ordered sequence of stations such that the precedence relations among. Assembly line balancing alb problem is an assignment problem aiming to assign the tasks to the stations in order to minimize the cycle time, i. Configuring an assembly line is a complicated process, and optimizing that system is an important part of many manufacturing business models. Final results of assembly line balancing problem waldemar grzechca the silesian university of technology poland 1. The goal is to achieve the desired output rate with the smallest number of workstations. It was designed to be an efficient, highly productive way. The purpose of this study is to first investigate the efficiency of the most commonly used performance measures for minimizing the number of workstations nws in approaches addressing simple assembly line balancing problem salbp for both straight and ushaped line, and second to provide a comparative evaluation of 20 constructive heuristics to find solutions to the salbp1. This video has been prepared to assist my students at indiana university of pennsylvania iup, located in western pennsylvania near pittsburgh usa.
In this paper, a new line design hybrid of utype and twosided lines is presented. Linearprogramming solutions to the assemblyline balancing problem are offered in two forms. The assembly line balancing problem is one of assigning all tasks to a series of workstations so that each workstations has no more than can be done in their cycle time. Assembly line balancing problem of sewing lines in garment. Optimization of cycle time in an assembly line balancing problem. Solving large singlemodel assembly line balancing problemsa. The original assembly line was strictly paced and straight singlemodel lines. Many papers have been published on computerorientated methods for solving singlemodel assembly line balancing.
The decision problem of optimally partitioning balancing the assembly work among the stations with respect to some objective is known as the assembly line balancing problem albp. Assembly line balancing can be loosely defined as the process of optimizing an assembly line with regard to certain factors. Assembly line design and balancing designing and balancing the audi b9 mirror assembly line at smr automotive mirrors technology, mosonszolnok, hungary master of science thesis in the masters programme production engineering ranjith raja department of product and production development division of production systems. A mathematical programming model of the assembly line.
Key words assembly line balancing, ant colony optimization, heuristics. The unassigned time idle across all workstations is minimised. Heuristics for mixed model assembly line balancing problem. Dec 04, 2012 line balancing line balancing is levelling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. In this paper, a multiobjective genetic agorithm to solve assembly line balancing problems is proposed.
442 494 1440 84 44 1342 829 539 828 1126 1411 362 1219 680 1385 363 651 258 1463 759 91 920 732 1226 389 777 321 1160 10 778 217