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A realistic multi-manned five-sided mixed-model assembly line balancing and scheduling problem with moving workers and limited workspace

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  • Bahman Naderi
  • Ahmed Azab
  • Katayoun Borooshan

Abstract

The assembly line balancing problem can completely vary from one production line to the other. This paper deals with a realistic assembly line for the automotive industry inspired by Fiat Chrysler Automotive in North America and Parskhodro in Iran (both large-scale automotive companies). This problem includes some specific requirements that have not been studied in the literature. For example, the assembly line is five-sided, and workers can move along these sides. Due to the limited workspace, all the sides cannot work simultaneously at one station. First, a mixed integer linear programming model is proposed for the problem. Then, the model is improved to have a tighter linear relaxation. Moreover, an effective logic-based Benders’ decomposition algorithm is developed. After careful analysis of problem’s structure, three propositions are introduced. The master problem is well restricted by eight valid inequalities. Two different sub-problem types are defined to extract more information from the master problem’s solution. In this case, the algorithm adds effective cuts that reduce the solution space to the extent possible at each iteration. Thus, the number of iterations is significantly cut down. The performance of the model and algorithm, as well as improvement made on both, is evaluated.

Suggested Citation

  • Bahman Naderi & Ahmed Azab & Katayoun Borooshan, 2019. "A realistic multi-manned five-sided mixed-model assembly line balancing and scheduling problem with moving workers and limited workspace," International Journal of Production Research, Taylor & Francis Journals, vol. 57(3), pages 643-661, February.
    • Handle: RePEc:taf:tprsxx:v:57:y:2019:i:3:p:643-661
    DOI: 10.1080/00207543.2018.1476786
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    Citations

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    Cited by:

    1. Michels, Adalberto Sato & Lopes, Thiago Cantos & Magatão, Leandro, 2020. "An exact method with decomposition techniques and combinatorial Benders’ cuts for the type-2 multi-manned assembly line balancing problem," Operations Research Perspectives, Elsevier, vol. 7(C).
    2. Hassan Zohali & Bahman Naderi & Vahid Roshanaei, 2022. "Solving the Type-2 Assembly Line Balancing with Setups Using Logic-Based Benders Decomposition," INFORMS Journal on Computing, INFORMS, vol. 34(1), pages 315-332, January.
    3. 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).
    4. 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).
    5. Murat Şahin & Talip Kellegöz, 2023. "Benders’ decomposition based exact solution method for multi-manned assembly line balancing problem with walking workers," Annals of Operations Research, Springer, vol. 321(1), pages 507-540, February.
    6. Battaïa, Olga & Dolgui, Alexandre, 2022. "Hybridizations in line balancing problems: A comprehensive review on new trends and formulations," International Journal of Production Economics, Elsevier, vol. 250(C).

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