RESOURCE-CONSTRAINED ASSEMBLY LINE BALANCING PROBLEM AND AN APPLICATION IN AN ASSEMBLY LINE

Year 2025, Volume: 33 Issue: 2, 1819 - 1831, 22.08.2025

Mehmet Ceylan , Seda Hezer

https://doi.org/10.31796/ogummf.1607331

Abstract

One of the most important ways to increase productivity in industrial manufacturing is the efficient design of assembly lines. These lines consist of workstations connected by moving belts or conveyors where products are assembled part by part to reach their final form. In today's competitive manufacturing environment, organizing the work to be performed at these stations in the most efficient way is critically important. This organization process is called the “Assembly Line Balancing Problem (ALBP)” and primarily focuses on two main objectives: minimizing the number of workstations and cycle time. However, recently, this classical approach has given way to a more comprehensive perspective. Now, the optimization of resources such as workers, machines, equipment, and energy is also included in the problem. This advanced problem is termed the “Resource-Constrained ALBP (RCALBP)”. Within the scope of this study, the “Multi-Model RCALBP (MRCALBP)” was implemented in a company manufacturing industrial kitchen machines. Based on a known mathematical model in the RCALBP literature, a solution has been developed adapted to the specific needs of the company. Successful results were achieved through optimization work using 19 different resources for four different products. Two separate production lines were merged into one line, total number of resources was reduced from 46 to 31, and the number of workers was decreased from 4 to 2. At least 49% improvement in total costs has been achieved for each product. This study demonstrates that theoretical models can be successfully applied in real life and provide tangible benefits.

Keywords

Assembly Line Balancing , Industrial Case Study , Multi-Model Products , Resource-Constrained

KAYNAK KISITLI MONTAJ HATTI DENGELEME PROBLEMİ VE BİR İŞLETMEDE UYGULAMASI

Abstract

Endüstriyel üretimde verimliliği artırmanın en önemli yollarından biri, montaj hatlarının etkin bir şekilde tasarlanmasıdır. Bu hatlar, ürünlerin parça parça birleştirilerek son halini aldığı, hareketli bantlar veya konveyörlerle birbirine bağlı iş istasyonlarından oluşur. Günümüzün rekabetçi üretim ortamında, bu istasyonlarda yapılacak işlerin en verimli şekilde düzenlenmesi kritik öneme sahiptir. Bu düzenleme sürecine "Montaj Hattı Dengeleme Problemi (MHDP)" adı verilir ve temel olarak iş istasyonu sayısını ve çevrim süresini en aza indirmek olmak üzere iki ana hedef gözetilir. Ancak son dönemde, bu klasik yaklaşım yerini daha kapsamlı bir bakış açısına bırakmıştır. Artık işçi, makine, ekipman ve enerji gibi kaynakların optimize edilmesi de probleme dahil edilmektedir. Bu gelişmiş problem, "Kaynak Kısıtlı MHDP (KKMHDP)" olarak adlandırılmaktadır. Bu çalışma kapsamında, “Çok Modelli KKMHDP (ÇKKMHDP)” endüstriyel mutfak ekipmanları üreten bir işletmede uygulanmıştır. KKMHDP literatüründe bilinen bir matematiksel model temel alınarak, işletmenin özel ihtiyaçlarına göre uyarlanmış bir çözüm geliştirilmiştir. Dört farklı ürün için 19 çeşit kaynak kullanılarak yapılan optimizasyon çalışması ile başarılı sonuçlar elde edilmiştir. İki ayrı üretim hattı tek hatta birleştirilmiş, toplam ekipman sayısı 46'dan 31'e düşürülmüş ve çalışan sayısı 4'ten 2'ye indirilmiştir. Her ürün için toplam maliyetlerde en az %49'luk bir iyileşme sağlanmıştır. Bu çalışma, teorik modellerin gerçek hayatta başarıyla uygulanabileceğini ve somut faydalar sağlayabileceğini ortaya koymaktadır.

Keywords

Montaj Hattı Dengeleme , Endüstriyel Vaka Çalışması , Çok Modelli Ürünler , Kaynak Kısıtlı

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