Search Results (3)

With the rapid transformation of the automotive industry towards electric vehicles, how to achieve efficient mixed-line production of electric vehicles and fuel vehicles has become a key challenge for modern assembly systems. This study investigated the balancing problem of a mixed-model multi-manned assembly line, considering workstation sharing (MMuALBP-WS), and developed a deterministic multi-objective model that integrates the heterogeneity of tasks and the coordination of shared workstations. An improved genetic algorithm was proposed, whose decoding mechanism enables different types of electric vehicle and fuel vehicle tasks to achieve dynamic collaboration within the shared workstations. A real case study from the chassis assembly line of Company W demonstrated the effectiveness of the proposed method, achieving a 25% reduction in the number of workstations, a 27% decrease in the total number of workers, and a 23.56% increase in average workstation utilization. The results confirmed that the workstation sharing mechanism significantly improved production balance, labor utilization, and flexibility, providing a practical and scalable optimization framework for the mixed-model assembly system in the era of the transition from electric vehicles to fuel vehicles. In addition to its practical significance, this study enhances the understanding of mixed-model multi-manned line balancing by incorporating workstation-sharing logic into both the mathematical modeling and optimization process, offering a theoretical basis for future extensions to more complex production environments. Full article

Industrial progress has increased the need to improve the productivity of production systems. In this context, optimizing the problem of allocating and balancing workers on a multi-manned assembly line (MALW-a-BP) is a major challenge. This paper introduces a mathematical model for this issue, as well as a hybrid genetic algorithm (h-GA) dedicated to its solution, with a particular focus on multi-objective optimization, which includes minimizing the cycle time and the total squared workload. Experimental results show that the proposed method outperforms the classical version of the GA, thus confirming the robustness and efficiency of the h-GA. Full article

The assembly of large and complex products such as cars, trucks, and white goods typically involves a huge amount of production resources such as workers, pieces of equipment, and layout areas. In this context, multi-manned workstations commonly characterize these assembly lines. The simultaneous operators’ activity in the same assembly station suggests considering compatibility/incompatibility between the different mounting positions, equipment sharing, and worker cooperation. The management of all these aspects significantly increases the balancing problem complexity due to the determination of the start/end times of each task. This paper proposes a new mixed-integer programming model to simultaneously optimize the line efficiency, the line length, and the workload smoothness. A customized procedure based on a simulated annealing algorithm is developed to effectively solve this problem. The aforementioned procedure is applied to the balancing of the real assembly line of European sports car manufacturers distinguished by 665 tasks and numerous synchronization constraints. The experimental results present remarkable performances obtained by the proposed procedure both in terms of solution quality and computation time. The proposed approach is the practical reference for efficient multi-manned assembly line design, task assignment, equipment allocation, and mounting position management in the considered industrial fields. Full article