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Workforce Planning in Mixed Model Assembly Systems

Author

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  • Chung-Yee Lee

    (Texas A&M University College Station, Texas)

  • George L. Vairaktarakis

    (Marquette University, Milwaukee, Wisconsin)

Abstract

Serial assembly systems are formed by arranging several production cells or stations in series. We study a popular class of serial assembly lines where all stations have the same production cycle. We address a workforce planning problem for such lines which finds applications in labor-intensive operations in automobile, fire engine, aircraft, and PC board assembly. The problem presented can be applied to lines that produce several variations of a basic stable design; i.e., mixed model transfer lines. Given a set of n jobs, we want to find a sequence that minimizes the maximum workforce requirements over all production cycles. An optimal polynomial algorithm for the two-station line is presented, and the three-station case is proved to be strongly (N-script)(P-script)-complete. Several heuristic algorithms that produce upper and lower bounds are developed for the general problem. Worst case behavior of the upper bounds, as well as average performance of lower and upper bounds, are reported. Computational results show that some of the heuristics produce near optimal solutions. As an extension of the basic model we exploit the tradeoff between cycle time and workforce level.

Suggested Citation

  • Chung-Yee Lee & George L. Vairaktarakis, 1997. "Workforce Planning in Mixed Model Assembly Systems," Operations Research, INFORMS, vol. 45(4), pages 553-567, August.
    • Handle: RePEc:inm:oropre:v:45:y:1997:i:4:p:553-567
    DOI: 10.1287/opre.45.4.553
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    Citations

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    Cited by:

    1. Heike, G. & Ramulu, M. & Sorenson, E. & Shanahan, P. & Moinzadeh, K., 2001. "Mixed model assembly alternatives for low-volume manufacturing: The case of the aerospace industry," International Journal of Production Economics, Elsevier, vol. 72(2), pages 103-120, July.
    2. Hashemi-Petroodi, S. Ehsan & Thevenin, Simon & Kovalev, Sergey & Dolgui, Alexandre, 2022. "Model-dependent task assignment in multi-manned mixed-model assembly lines with walking workers," Omega, Elsevier, vol. 113(C).
    3. Jérémie Gallien & Serguei Netessine & Maher Lahmar & Hakan Ergan & Sergei V. Savin & Michael J. Fry, 2001. "The MSOM Society Student Paper Competition: Extended Abstracts of 2000 Winners," Manufacturing & Service Operations Management, INFORMS, vol. 3(1), pages 1-1.
    4. George L. Vairaktarakis & Chung‐Yee Lee, 2004. "Analysis of algorithms for two‐stage flowshops with multi‐processor task flexibility," Naval Research Logistics (NRL), John Wiley & Sons, vol. 51(1), pages 44-59, February.
    5. Jesús F. Lampón & Pablo Cabanelas & Javier González Benito, 2015. "The impact of implementation of a modular platform strategy in automobile manufacturing networks," Working Papers. Collection B: Regional and sectoral economics 1502, Universidade de Vigo, GEN - Governance and Economics research Network.
    6. A Lim & Z Xu, 2009. "Searching optimal resequencing and feature assignment on an automated assembly line," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 60(3), pages 361-371, March.
    7. George Vairaktarakis & Joseph G. Szmerekovsky & Jiayan Xu, 2016. "Level workforce planning for multistage transfer lines," Naval Research Logistics (NRL), John Wiley & Sons, vol. 63(7), pages 577-590, October.
    8. Xiaobo Zhao & Katsuhisa Ohno & Hon‐Shiang Lau, 2004. "A balancing problem for mixed model assembly lines with a paced moving conveyor," Naval Research Logistics (NRL), John Wiley & Sons, vol. 51(3), pages 446-464, April.
    9. Zhilan Lou & Wanchen Jie & Shuzhu Zhang, 2020. "Multi-Objective Optimization for Order Assignment in Food Delivery Industry with Human Factor Considerations," Sustainability, MDPI, vol. 12(19), pages 1-17, September.
    10. Sayin, Serpil & Karabati, Selcuk, 2007. "Assigning cross-trained workers to departments: A two-stage optimization model to maximize utility and skill improvement," European Journal of Operational Research, Elsevier, vol. 176(3), pages 1643-1658, February.
    11. Delorme, Xavier & Dolgui, Alexandre & Kovalev, Sergey & Kovalyov, Mikhail Y., 2019. "Minimizing the number of workers in a paced mixed-model assembly line," European Journal of Operational Research, Elsevier, vol. 272(1), pages 188-194.
    12. Xiaobo Zhao & Jianyong Liu & Katsuhisa Ohno & Shigenori Kotani, 2007. "Modeling and analysis of a mixed‐model assembly line with stochastic operation times," Naval Research Logistics (NRL), John Wiley & Sons, vol. 54(6), pages 681-691, September.
    13. Eylem Tekin & Wallace J. Hopp & Mark P. Van Oyen, 2002. "Benefits of Skill Chaining in Production Lines with Cross-Trained Workers: An Extended Abstract," Manufacturing & Service Operations Management, INFORMS, vol. 4(1), pages 17-20.
    14. Wallace J. Hopp & Eylem Tekin & Mark P. Van Oyen, 2004. "Benefits of Skill Chaining in Serial Production Lines with Cross-Trained Workers," Management Science, INFORMS, vol. 50(1), pages 83-98, January.
    15. Dolgui, Alexandre & Kovalev, Sergey & Kovalyov, Mikhail Y. & Malyutin, Sergey & Soukhal, Ameur, 2018. "Optimal workforce assignment to operations of a paced assembly line," European Journal of Operational Research, Elsevier, vol. 264(1), pages 200-211.
    16. Vairaktarakis, George L. & Cai, Xiaoqiang & Lee, Chung-Yee, 2002. "Workforce planning in synchronous production systems," European Journal of Operational Research, Elsevier, vol. 136(3), pages 551-572, February.

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