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

Yıl 2024, Sayı: 056, 3 - 22, 31.03.2024

Gözde Kurada Derya Deliktaş

https://doi.org/10.59313/jsr-a.1354104

Öz

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.

Anahtar Kelimeler

Genetic Algorithm, Assembly Line Worker Assignment and Balancing, irace, Design of Experimental Design, Type-2

Kaynakça

• [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
• [7] Karp, R. M., Reducibility among combinatorial problems. In R. E. Miller, J. W. Thatcher and J. D. Bohlinger (Eds.), Complexity of computer computations. New York: Plenum Press, pp. 85-103,1972
• [8] Doğan, A. and Sakallı, Ü.S., Bulanık işlem zamanlı geleneksel montaj hattı dengeleme problemi için yeni bir yaklaşım: Savunma sanayii uygulaması. Kırıkkale Üniversitesi Uluslararası Mühendislik Araştırma ve Geliştirme Dergisi, 8(1), 31-50,2016
• [9] Mutlu, Ö., Polat, O. and Supciller, A.A.,An iterative genetic algorithm for the assembly line worker assignment and balancing problem of type-II. Computers & Operations Research, 40(1), 418-426. URL: https://doi.org/10.1016/j.cor.2012.07.010 ,2013
• [10] Tinç, H.K.,An Algebraic Approach to Sensitivity Analysis in Linear Programming. Unpublished Master’s Thesis, İstanbul Technical University Institute of Science and Technology, İstanbul.,2007
• [11] Karsu, Ö. and Azizoğlu, M., Bicriteria multiresource generalized assignment problem. Naval Research Logistics (NRL), 61(8), 621-636. URL: https://doi.org/10.1002/nav.21607 ,2014a
• [12] Altunay, H., Özmutlu, H.C. and Özmutlu, S., Paralel görev atamalı montaj hattı dengeleme problemi için yeni bir matematiksel model önerisi. Cumhuriyet Üniversitesi İktisadi ve İdari Bilimler Dergisi, 18(1), 15-33,2017
• [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
• [39] Katiraee, N., Calzavara, M., Finco, S. and Battini, D., Consideration of workforce differences in assembly line balancing and worker assignment problem. IFAC PapersOnLine, 54(1), 13–18. URL: https://doi.org/10.1016/j.ifacol.2021.08.002, 2021
• [40] Küçükkoç, İ. , Karışık modelli montaj hattı dengeleme problemleri ve genetik algoritmalar ile bir uygulama. Yayımlanmamış Yüksek Lisans Tezi, Balıkesir Üniversitesi Fen Bilimleri Enstitüsü, Balıkesir. URL: https://hdl.handle.net/20.500.12462/2560, 2011
• [41] Akpınar, S. and Bayhan, G.M., A hybrid genetic algorithm for mixed model assembly line balancing problem with parallel workstations and zoning constraints. Engineering Applications of Artificial Intelligence, 24(3), 449-457. URL: https://doi.org/10.1016/j.engappai.2010.08.006, 2011
• [42] Moreira, M.C.O., Ritt, M., Costa, A.M. and Chaves, A.A., Simple heuristics for the assembly line worker assignment and balancing problem. Journal of Heuristics, 18, 505–524. URL: https://doi.org/10.1007/s10732-012-9195-5, 2012
• [43] Oksuz, M. K., Buyukozkan, K. and Satoglu, S. I., U-shaped assembly line worker assignment and balancing problem: A mathematical model and two metaheuristics. Computers & Industrial Engineering, 112, 246–263. URL: https://doi.org/10.1016/j.cie.2017.08.030, 2017
• [44] Fathi, M., Nourmohammadi, A., HC Ng, A., Syberfeldt, A. and Eskandari, H., An improved genetic algorithm with variable neighborhood search to solve the assembly line balancing problem. Engineering Computations, 37(2), 501-521. URL: https://doi.org/10.1108/EC-02-2019-0053, 2019
• [45] Liu, R., Liu, M., Chu, F., Zheng, F. and Chu, C., Eco-friendly multi-skilled worker assignment and assembly line balancing problem. Computers & Industrial Engineering, 151(2), 106944. URL: https://doi.org/10.1016/j.cie.2020.106944 , 2021
• [46] Kılınçcı, Ö., Assembly line balancing problem with resource and sequence-dependent setup times (ALBPRS). Journal of the Faculty of Engineering and Architecture of Gazi University, 38(1), 557-570. URL: https://doi.org/10.17341/gazimmfd.757276, 2022
• [47] Andres, C., Miralles C. and Pastor, R., Balancing and scheduling tasks in assembly lines with sequence-dependent setup times. European Journal of Operational Research, 187 (3), 1212–1223. URL: https://doi.org/10.1016/j.ejor.2006.07.044 , 2008
• [48] Miettinen, K., Survey of methods to visualize alternatives in multiple criteria decision-making problems. OR Spectrum. 36(1), 3–37. URL: https://doi.org/10.1007/s00291-012-0297-0 , 2014
• [49] Miralles, C., García-Sabater, J. P., Andrés, C. and Cardós, M., Branch and bound procedures for solving the assembly line worker assignment and balancing problem: application to sheltered work centers for disabled. Discrete Applied Mathematics, 156(3), 352–367. URL: https://doi.org/10.1016/j.dam.2005.12.012 , 2008
• [50] Scholl, A and Voß, S., Simple assembly line balancing—heuristic approaches. Journal of Heuristics, 2(3), 217–244. URL: https://doi.org/10.1007/BF00127358 , 1997
• [51] Yavuz, G., L-shade algoritmasının otomatik parametre yapılandırma yöntemi ile iyileştirilmesi. Bilişim Teknolojileri Dergisi, 15(2), 189-197. URL: https://doi.org/10.17671/gazibtd.1034921, 2022
• [52] Marler, RT. and Arora, J.S., Function-transformation methods for multi-objective optimization. Engineering Optimization, 37(6), 551–570. URL: https://doi.org/10.1080/03052150500114289, 2005
• [53] Ross, P. J., Taguchi techniques for quality engineering: loss function, orthogonal experiments, parameter and tolerance design (1rd ed.). USA: The McGraw-Hill Companies Inc, 1988
• [54] Deliktaş, D. and Aydın, D., An artificial bee colony based-hyper heuristic algorithm with local search for the assembly line balancing problems. Engineering Computations, In Press, URL: https://doi.org/10.1108/EC-02-2023-0075, 2023