Assembly line balancing with sequence-dependent setup times by considering deterioration and learning effects

Berrin Atalay; Gülhan Toğa; M. Duran Toksarı

Assembly line balancing with sequence-dependent setup times by considering deterioration and learning effects

Abstract

In this paper, we addressed an approach for Simple Assembly Line Balancing Problem (SALBP) with simultaneous effects of deterioration and learning by considering the sequence-dependent setup times for tasks at the first time in the SALBP literature. Sequence-dependent setup times increase the global workstation times depending on assignment of a task next to another at the same workstation. The setup time as the time required to switch between activities in a workstation must be added to the processing time of the activities while minimizing the workstation numbers in assembly lines. On the other hand, deterioration and learning effects change the global workstation time in reality. Processing time of a task decreases while repeating the same activity continuously by workers/machines, although actual processing time is defined as a function of starting time of a task due to the deterioration effect. A mathematical model for SALBP-1 is developed which aims the minimization of workstation number in assembly line. Moreover NP-hard nature of the problem, mathematical model is insufficient. Ranked Positional Weight Method (RPWM) and Computer Method of Sequencing Operation for Assembly Line (COMSOAL) algorithms are used to handle with this problem and tested for different known data sets. Results indicate that our approach is very efficient to solve assembly line balancing problems (ALBP) with sequence-dependent setup times by considering deterioration and learning effects.

Keywords

References

P. Sivasankaran and P. Shahabudeen, “Literature review of assembly line balancing problems,” Int. J. Adv. Manuf. Technol., vol. 73, no. 9, pp. 1665–1694, Aug. 2014, doi: 10.1007/s00170-014-5944-y.
S. Akpınar, G. Mirac Bayhan, and A. Baykasoglu, “Hybridizing ant colony optimization via genetic algorithm for mixed-model assembly line balancing problem with sequence dependent setup times between tasks,” Appl. Soft Comput., vol. 13, no. 1, pp. 574–589, Jan. 2013, doi: 10.1016/j.asoc.2012.07.024.
N. Boysen, M. Fliedner, and A. Scholl, “A classification of assembly line balancing problems,” Eur. J. Oper. Res., vol. 183, no. 2, pp. 674–693, Dec. 2007, doi: 10.1016/j.ejor.2006.10.010.
C. Andrés, C. Miralles, and R. Pastor, “Balancing and scheduling tasks in assembly lines with sequence-dependent setup times,” Eur. J. Oper. Res., vol. 187, no. 3, pp. 1212–1223, Jun. 2008, doi:10.1016/j.ejor.2006.07.044.
L. Martino and R. Pastor, “Heuristic procedures for solving the general assembly line balancing problem with setups,” Int. J. Prod. Res., vol. 48, no. 6, pp. 1787–1804, Mar. 2010, doi:10.1080/00207540802577979.
U. Özcan and B. Toklu, “Balancing two-sided assembly lines with sequence-dependent setup times,” Int. J. Prod. Res., vol. 48, no. 18, pp. 5363–5383, Sep. 2010, doi: 10.1080/00207540903140750.
S. A. Seyed-Alagheband, S. M. T. F. Ghomi, and M. Zandieh, “A simulated annealing algorithm for balancing the assembly line type II problem with sequence-dependent setup times between tasks,” Int. J. Prod. Res., vol. 49, no. 3, pp. 805–825, Feb. 2011, doi: 10.1080/00207540903471486.
A. Yolmeh and F. Kianfar, “An efficient hybrid genetic algorithm to solve assembly line balancing problem with sequencedependent setup times,” Comput. Ind. Eng., vol. 62, no. 4, pp. 936–945, May 2012, doi:10.1016/j.cie.2011.12.017.

A. Scholl, N. Boysen, and M. Fliedner, “The assembly line balancing and scheduling problem with sequence-dependent setup times: problem extension, model formulation and efficient heuristics,” Spectr., vol. 35, no. 1, pp. 291–320, Jan. 2013, doi: 10.1007/s00291-011-0265-0.
N. Hamta, S. M. T. Fatemi Ghomi, F. Jolai, and M. Akbarpour Shirazi, “A hybrid PSO algorithm for a multi-objective assembly line balancing problem with flexible operation times, sequencedependent setup times and learning effect,” Int. J. Prod. Econ., vol. 141, no. 1, pp. 99–111, Jan. 2013, doi: 10.1016/j.ijpe.2012.03.013.
N. Hamta, “A hybrid meta-heuristic for balancing and scheduling assembly lines with sequence-independent setup times by considering deterioration tasks and learning e ect,” Sci. Iran., p. 17, 2014.
M. Şahin and T. Kellegöz, “Increasing production rate in U-type assembly lines with sequence-dependent set-up times,” Eng. Optim., vol. 49, no. 8, pp. 1401–1419, Aug. 2017, doi:10.1080/0305215X.2016.1256394.
Y. Delice, E. K. Aydoğan, İ. Söylemez, and U. Özcan, “An ant colony optimisation algorithm for balancing two-sided U-type assembly lines with sequence-dependent set-up times,” Sādhanā, vol. 43, no. 12, p. 199, Nov. 2018, doi: 10.1007/s12046-018-0969-9.
U. Özcan, “Balancing and scheduling tasks in parallel assembly lines with sequence-dependent setup times,” Int. J. Prod. Econ., vol. 213, pp. 81–96, Jul. 2019, doi: 10.1016/j.ijpe.2019.02.023.
M. N. Janardhanan, Z. Li, G. Bocewicz, Z. Banaszak, and P. Nielsen, “Metaheuristic algorithms for balancing robotic assembly lines with sequence-dependent robot setup times,” Appl. Math. Model., vol. 65, pp. 256–270, Jan. 2019, doi: 10.1016/j. apm.2018.08.016.
J.-B. Wang, Y. Jiang, and G. Wang, “Single-machine scheduling with past-sequence-dependent setup times and effects of deterioration and learning,” Int. J. Adv. Manuf. Technol., vol. 41, no. 11, p. 1221, May 2008, doi: 10.1007/s00170-008-1512-7.
N. Yin, J.-B. Wang, D. Wang, L.-Y. Wang, and X.-Y. Wang, “Deteriorating jobs and learning effects on a single-machine scheduling with past-sequence-dependent setup times,” Int. J. Adv. Manuf. Technol., vol. 46, no. 5, pp. 707–714, Jan. 2010, doi: 10.1007/s00170-009-2116-6.
M. D. Toksarı, S. K. İşleyen, E. Güner, and Ö. F. Baykoç, “Assembly line balancing problem with deterioration tasks and learning effect,” Expert Syst. Appl., vol. 37, no. 2, pp. 1223–1228, Mar. 2010, doi:10.1016/j.eswa.2009.06.005. M. Duran Toksarı, S. K. İşleyen, E. Güner, and Ö. Faruk Baykoç, “Simple assembly line balancing problem under the combinations of the effects of learning and deterioration,” Assem. Autom., vol. 30, no. 3, pp. 268–275, Jan. 2010, doi: 10.1108/01445151011061163.
G. Mosheiov, “Scheduling problems with a learning effect,” Eur. J. Oper. Res., vol. 132, no. 3, pp. 687–693, Aug. 2001, doi: 10.1016/S0377-2217(00)00175-2.
D. Oron, “Single machine scheduling with simple linear deterioration to minimize total absolute deviation of completion times,” Comput. Oper. Res., vol. 35, no. 6, pp. 2071–2078, Jun. 2008, doi: 10.1016/j.cor.2006.10.010.
M. D. Toksarı, D. Oron, and E. Güner, “Single machine scheduling problems under the effects of nonlinear deterioration and timedependent learning,” Math. Comput. Model., vol. 50, no. 3, pp. 401–406, Aug. 2009, doi: 10.1016/j.mcm.2009.05.026.
M. Parichehreh, H. Gholizadeh, A. M. Fathollahi-Fard, and K. Y. Wong, “An energy-efficient unrelated parallel machine scheduling problem with learning effect of operators and deterioration of jobs,” Int. J. Environ. Sci. Technol., vol. 21, no. 15, pp. 9651–9676, 2024, doi: 10.1007/s13762-023-04979-7.
P. Chiniforooshan and D. Marinkovic, “A hybrid particle swarm optimization algorithm for single machine scheduling with sequence-dependent setup times and learning effects,” Comput. Algorithms Numer. Dimens., vol. 2, no. 2, pp. 74–86, 2023.
J. Pei, Y. Zhou, P. Yan, and P. M. Pardalos, “A concise guide to scheduling with learning and deteriorating effects,” Int. J. Prod. Res., vol. 61, no. 6, pp. 2010–2031, 2023, doi:10.1080/00207543.2022.2086329.
A. Scholl, Balancing and Sequencing of Assembly Lines, 2nd ed. Physica-Verlag Heidelberg, 1999.
D. Biskup, “Single-machine scheduling with learning considerations,” Eur. J. Oper. Res., vol. 115, no. 1, pp. 173–178, May 1999, doi: 10.1016/S0377-2217(98)00246-X.

Details

Primary Language

English

Subjects

Numerical and Computational Mathematics (Other), Operations Research İn Mathematics

Journal Section

Research Article

Authors

Berrin Atalay ^*
Türkiye

Gülhan Toğa
Türkiye

M. Duran Toksarı
Türkiye

Publication Date

January 31, 2026

Submission Date

May 29, 2025

Acceptance Date

July 29, 2025

Published in Issue

Year 2026 Volume: 3 Number: 1

IZ

https://izlik.org/JA68LK52AC

Cite

RIS / Bibtex

APA

Atalay, B., Toğa, G., & Toksarı, M. D. (2026). Assembly line balancing with sequence-dependent setup times by considering deterioration and learning effects. Hitit Journal Of Science, 3(1). https://izlik.org/JA68LK52AC

AMA

1.Atalay B, Toğa G, Toksarı MD. Assembly line balancing with sequence-dependent setup times by considering deterioration and learning effects. HJS. 2026;3(1). https://izlik.org/JA68LK52AC

Chicago

Atalay, Berrin, Gülhan Toğa, and M. Duran Toksarı. 2026. “Assembly Line Balancing With Sequence-Dependent Setup Times by Considering Deterioration and Learning Effects”. Hitit Journal Of Science 3 (1). https://izlik.org/JA68LK52AC.

EndNote

Atalay B, Toğa G, Toksarı MD (January 1, 2026) Assembly line balancing with sequence-dependent setup times by considering deterioration and learning effects. Hitit Journal Of Science 3 1

IEEE

[1]B. Atalay, G. Toğa, and M. D. Toksarı, “Assembly line balancing with sequence-dependent setup times by considering deterioration and learning effects”, HJS, vol. 3, no. 1, Jan. 2026, [Online]. Available: https://izlik.org/JA68LK52AC

ISNAD

Atalay, Berrin - Toğa, Gülhan - Toksarı, M. Duran. “Assembly Line Balancing With Sequence-Dependent Setup Times by Considering Deterioration and Learning Effects”. Hitit Journal Of Science 3/1 (January 1, 2026). https://izlik.org/JA68LK52AC.

JAMA

1.Atalay B, Toğa G, Toksarı MD. Assembly line balancing with sequence-dependent setup times by considering deterioration and learning effects. HJS. 2026;3. Available at https://izlik.org/JA68LK52AC.

MLA

Atalay, Berrin, et al. “Assembly Line Balancing With Sequence-Dependent Setup Times by Considering Deterioration and Learning Effects”. Hitit Journal Of Science, vol. 3, no. 1, Jan. 2026, https://izlik.org/JA68LK52AC.

Vancouver

1.Berrin Atalay, Gülhan Toğa, M. Duran Toksarı. Assembly line balancing with sequence-dependent setup times by considering deterioration and learning effects. HJS [Internet]. 2026 Jan. 1;3(1). Available from: https://izlik.org/JA68LK52AC