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Developing a multi-objective genetic optimisation approach for an operational design of a manual mixed-model assembly line with walking workers

Author

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  • Atiya Al-Zuheri

    (University of South Australia
    Ministry of Science and Technology)

  • Lee Luong

    (University of South Australia)

  • Ke Xing

    (University of South Australia)

Abstract

A walking worker assembly line (WWAL), in which each cross-trained worker travels along the line to carry out all required tasks, is an example of lean system, specifically designed to respond quickly and economically to the fluctuating nature of market demands. Because of the complexity of WWAL design problems, classical heuristic approaches are not capable of solving problematic design characteristic of WWAL of very large design space. This paper presents a new genetic approach to address the mixed model walking worker manual assembly line optimisation design problem with multiple objectives. The aim is to select a set of operational variables to perform to the required demand for two product models. The goal is to produce the required models at the lowest cost possible, whilst keeping within an ergonomically balanced operation. Genetic algorithms are developed to tackle this problem. This paper describes the fundamental structure of this approach, as well as the influence of the crossover probability, the mutation probability and the size of the population on the performance of the genetic algorithm. The paper also presents an application of a developed algorithm to the operational design problem of plastic electrical box assembly line.

Suggested Citation

  • Atiya Al-Zuheri & Lee Luong & Ke Xing, 2016. "Developing a multi-objective genetic optimisation approach for an operational design of a manual mixed-model assembly line with walking workers," Journal of Intelligent Manufacturing, Springer, vol. 27(5), pages 1049-1065, October.
    • Handle: RePEc:spr:joinma:v:27:y:2016:i:5:d:10.1007_s10845-014-0934-3
    DOI: 10.1007/s10845-014-0934-3
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    References listed on IDEAS

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    1. Scholl, Armin & Fliedner, Malte & Boysen, Nils, 2010. "Absalom: Balancing assembly lines with assignment restrictions," European Journal of Operational Research, Elsevier, vol. 200(3), pages 688-701, February.
    2. Qian Wang & Ling Pan & Antony Roy Mileham & Geraint Wyn Owen & Linda Blyth Newnes & Christopher Reginald Chatwin, 2007. "Modelling randomness of a manual assembly system with walking workers," International Journal of Industrial and Systems Engineering, Inderscience Enterprises Ltd, vol. 2(2), pages 195-210.
    3. Atiya Al-Zuheri & Ke Xing & Lee Luong, 2013. "Mathematical modelling for process design of walking worker assembly line in productivity and ergonomics perspectives," International Journal of Industrial and Systems Engineering, Inderscience Enterprises Ltd, vol. 14(1), pages 104-137.
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    Cited by:

    1. 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).
    2. Hashemi-Petroodi, S. Ehsan & Thevenin, Simon & Kovalev, Sergey & Dolgui, Alexandre, 2023. "Markov decision process for multi-manned mixed-model assembly lines with walking workers," International Journal of Production Economics, Elsevier, vol. 255(C).

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