Abstract
Industry 4.0 is transforming how costs, including labor costs, are managed in manufacturing and remanufacturing systems. Managers must balance assembly lines and reduce the training time of workstation operators to achieve sustainable operations. This study’s originality lies in its use of an algorithm to balance an assembly line by matching operators to workstations so that the line’s workstations achieve the same targeted output rates. First, the maximum output rate of the assembly line is found, and then the number of operators needed at each workstation is determined. Training time is reduced by matching operators’ training and skills to workstations’ skill requirements. The study obtains a robust, cluster algorithm based on the concept of group technology, then forms operator skill cells and determines operator families. Four numerical examples are presented to demonstrate the algorithm’s implementation. The proposed algorithm can solve the problem of arranging operators to balance assembly lines. Managers can also solve the problem of worker absences by assigning more than one operator with the required skillset to each workstation and rearranging them as needed.
Highlights
Netessine and Taylor [1] demonstrated that expensive production technology usually leads to low product prices and may simultaneously lead to high-quality products
This study initially considers a traditional assembly line that has four workstations with Tohuitspusttusdλy,inλiti,alλly,caonndsidλers(Faigtruardei1ti)o. nTahluass,stehmebplryoldinuecttihoantrhaates,forurouwtopruktsrtateio, nosf twhisthasosuetmpubtlys λliAne, λisBe, qλuCa, latnodλλD (F=igmuirne. 1{λ)
Tpoarneydmucaenlaagbeorrscaoimstst,oaancahsiseevme sbulystlainineamblaenoapgeerraitniocnresa, pseasrtthoef wlinheic’sheisffimciaennacgying andlarbeodruccoesstst.hTeotraeidnuincegltaibmoer ncoesetdse, danbayssoepmerbaltyolrisn.eInmaadneaqgueartientcrraeiansiensgthoer ldiniset’rsaecftfiiocniesn, cy and reduces the training time needed by operators
Summary
Netessine and Taylor [1] demonstrated that expensive production technology usually leads to low product prices and may simultaneously lead to high-quality products. The product price is usually proportional to the product cost, part of which is labor cost. Line balancing (ALB) is a crucial part of production/operations management [2]. On most mass-production assembly lines, workers repetitively perform a set of tasks predefined by using assembly line balancing techniques [3], which assign a number of work elements to various workstations to maximize the assembly line’s balancing efficiency [4]. An operator without adequate training or who is focused on personal problems can cause an accident, decrease the efficiency of the assembly line, and increase production costs. A balanced assembly line can reduce a factory’s work-in-process (WIP) inventory. Maximum productivity and minimum load smoothness are benefits of solving the assembly line balancing problem (ALBP) [8,9]
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a call
