Multi-Objective Assembly Line Balancing Problem with Setup Times Using Fuzzy Goal Programming and Genetic Algorithm

Abstract

Assembly lines are often indispensable in factories, and in order to attain a certain level of assembly line productivity, multiple goals must be considered at the same time. However, these multiple goals may conflict with each other, and this is a multi-objective assembly line balancing problem. This study considers four objectives, namely minimizing the cycle time, minimizing the number of workstations, minimizing the workload variance, and minimizing the workstation idle time. Since the objectives conflict with each other, for example, minimizing the cycle time may increase the number of workstations, the fuzzy multi-objective linear programming model is used to maximize the satisfaction level. When the problem becomes too complicated, it may not be solved by the fuzzy multi-objective linear programming model using a mathematical software package. Therefore, a genetic algorithm model is proposed to solve the problem efficiently. By studying practical cases of an automobile manufacturer, the results show that the proposed fuzzy multi-objective linear programming model and the genetic algorithm model can solve small-scale multi-objective assembly line balancing problems efficiently, and the genetic algorithm model can obtain good solutions for large-scale problems in a short computational time. Datasets from previous works are adopted to examine the applicability of the proposed models. The results show that both the fuzzy multi-objective linear programming model and the genetic algorithm model can solve the smaller problem cases and that the genetic algorithm model can solve larger problems. The proposed models can be applied by practitioners in managing a multi-objective assembly line balancing problem.