Ergonomic risk and cycle time minimization for the U-shaped worker assignment assembly line balancing problem: A multi-objective approach

Abstract

Workers still perform the bulk of operations in the manufacturing industry. The consideration of the assignment of workers and the reduction of ergonomic risks in U-shaped assembly lines is of paramount importance. However, the objectives of efficient task and worker assignment and a reduction in ergonomic risks are not usually correlated. Moreover, there is limited research in the existing literature into multi-objective approaches in U-shaped assembly lines. We formulate a U-shaped assembly worker assignment and balancing problem to simultaneously minimize cycle times and ergonomic risks. In addition, and due to its simplicity and successful results in flow shop scheduling problems, a Restarted Iterated Pareto Greedy algorithm is designed to optimize both objectives. In this algorithm, a problem-specific heuristic-based initialization is extended to improve the initial solution. Two precedence-based greedy and local search phases are developed to exploit the space around the current solution. Finally, a restart mechanism is proposed to help the algorithm escape from local optima. Comprehensive computational results, supported by detailed statistical analyses, suggest that the proposed multi-objective algorithm outperforms existing methods on a large number of benchmark instances.