A GA-based solution approach for balancing printed circuit board assembly lines

Printed circuit board (PCB) assembly lines consist of a number of different machines for mounting electronic components onto PCBs. While high-speed placement machines are employed to assemble standard components, so-called fine-pitch placement machines are used to mount complex electronic components with high precision and by use of specific nozzles. In this paper, we investigate a typical mass production environment where a single type of PCB is assembled in a line comprising high-speed as well as high-precision placement machines. The PCB assembly line balancing problem consists of assigning component feeders, each holding a specific electronic component type, and the corresponding placement operations to machines in the line so as to minimize the assembly cycle time. To solve this problem, a two-stage solution procedure based on genetic algorithm (GA) is proposed. In the first stage, component feeders are assigned to the placement machines with the objective of balancing the workload within the assembly line. A number of candidate solutions are then transmitted to the second stage, where specific machine optimization algorithms are applied to determine the feeder-slot assignment in the component magazine of the machines and the placement sequence of the various components. As a result, fine-tuned placement operation times are achieved which reflect the individual operation mode and the actual component setup of the placement machines. Finally, from the candidate solutions the one which minimizes the actual PCB assembly time is selected. © 2007 Springer-Verlag