Balancing Multi-Manned Assembly Lines With Walking Workers: Problem Definition, Mathematical Formulation, and an Electromagnetic Field Optimisation Algorithm

Assembly lines are widely used in industrial environments that produce standardised products in high volumes. Multi-manned assembly line is a special version of them that allows simultaneous operation of more than one worker at the same workstation. These lines are widely used in large-sized product manufacturing since they have many advantages over the simple one. This article has dealt with multi-manned assembly line balancing problem with walking workers for minimising the number of workers and workstations as the first and second objectives, respectively. A linear mixed-integer programming formulation of the problem has been firstly addressed after the problem definition is given. Besides that, a metaheuristic based on electromagnetic field optimisation algorithm has been improved. In addition to the classical electromagnetic field optimisation algorithm, a regeneration strategy has been applied to enhance diversification. A particle swarm optimisation algorithm from assembly line balancing literature has been modified to compare with the proposed algorithm. A group of test instances from many precedence diagrams were generated for evaluating the performances of all solution methods. Deviations from lower bound values of the number of workers/workstations and the number of optimal solutions obtained by these methods are concerned as performance criteria. The results obtained by the proposed programming formulations have been also compared with the solutions obtained by the traditional mathematical model of the multi-manned assembly line. Through the experimental results, the performance of the metaheuristic has been found very satisfactory according to the number of obtained optimal solutions and deviations from lower bound values. © 2019, © 2019 Informa UK Limited, trading as Taylor & Francis Group