Final Results of Assembly Line Balancing Problem

Abstract

The manufacturing assembly line was first introduced by Henry Ford in the early 1900’s. It was designed to be an efficient, highly productive way of manufacturing a particular product. The basic assembly line consists of a set of workstations arranged in a linear fashion, with each station connected by a material handling device. The basic movement of material through an assembly line begins with a part being fed into the first station at a predetermined feed rate. A station is considered any point on the assembly line in which a task is performed on the part. These tasks can be performed by machinery, robots, and/or human operators. Once the part enters a station, a task is then performed on the part, and the part is fed to the next operation. The time it takes to complete a task at each operation is known as the process time (Sury, 1971). The cycle time of an assembly line is predetermined by a desired production rate. This production rate is set so that the desired amount of end product is produced within a certain time period (Baybars, 1986). In order for the assembly line to maintain a certain production rate, the sum of the processing times at each station must not exceed the stations’ cycle time (Fonseca et al, 2005). If the sum of the processing times within a station is less than the cycle time, idle time is said to be present at that station (Erel et al,1998). One of the main issues concerning the development of an assembly line is how to arrange the tasks to be performed. This arrangement may be somewhat subjective, but has to be dictated by implied rules set forth by the production sequence (Kao, 1976). For the manufacturing of any item, there are some sequences of tasks that must be followed. The assembly line balancing problem (ALBP) originated with the invention of the assembly line. Helgeson et al (Helgeson et al, 1961) were the first to propose the ALBP, and Salveson (Salveson, 1955) was the first to publish the problem in its mathematical form. However, during the first forty years of the assembly line’s existence, only trial-and-error methods were used to balance the lines (Erel et al,, 1998). Since then, there have been numerous methods developed to solve the different forms of the ALBP. Salveson (Salveson, 1955) provided the first mathematical attempt by solving the problem as a linear program. Gutjahr and Nemhauser (Gutjahr & Nemhauser, 1964) showed that the ALBP problem falls into the class of NP-hard combinatorial optimization problems. This means that an optimal solution is not guaranteed for problems of significant size. Therefore, heuristic methods have become the most popular techniques for solving the problem.