Abstract
Different from a large number of existing studies in the literature, this paper addresses two important issues in managing production lines, the problems of line balancing and model sequencing, concurrently. A novel hybrid agent-based ant colony optimization–genetic algorithm approach is developed for the solution of mixed model parallel two-sided assembly line balancing and sequencing problem. The existing agent-based ant colony optimization algorithm is enhanced with the integration of a new genetic algorithm-based model sequencing mechanism. The algorithm provides ants the opportunity of selecting a random behavior among ten heuristics commonly used in the line balancing domain. A numerical example is given to illustrate the solution building procedure of the algorithm and the evolution of the chromosomes. The performance of the developed algorithm is also assessed through test problems and analysis of their solutions through a statistical test, namely paired sample t test. In accordance with the test results, it is statistically proven that the integrated genetic algorithm-based model sequencing engine helps agent-based ant colony optimization algorithm robustly find significantly better quality solutions.
Similar content being viewed by others
References
Kucukkoc I, Zhang DZ (2015) Balancing of Parallel U-shaped Assembly Lines, Computers and Operations Research, doi:10.1016/j.cor.2015.05.014
Ozdemir RG, Ayag Z (2011) An integrated approach to evaluating assembly-line design alternatives with equipment selection. Prod Plan Control 22(2):194–206
Battini D, Faccio M, Persona A, Sgarbossa F (2009) Balancing-sequencing procedure for a mixed model assembly system in case of finite buffer capacity. Int J Adv Manuf Technol 44(3-4):345–359
Thomopoulos NT (1967) Line balancing-sequencing for mixed-model assembly. Manag Sci 14(2):59–75
Akpinar S, Bayhan GM, Baykasoglu A (2013) Hybridizing ant colony optimization via genetic algorithm for mixed-model assembly line balancing problem with sequence dependent setup times between tasks. Appl Soft Comput 13(1):574–589
Kucukkoc I, Zhang DZ (2014) Simultaneous balancing and sequencing of mixed-model parallel two-sided assembly lines. Int J Prod Res 52(12):3665–3687
Erel E, Gokcen H (1999) Shortest-route formulation of mixed-model assembly line balancing problem. Eur J Oper Res 116(1):194–204
Matanachai S, Yano CA (2001) Balancing mixed-model assembly lines to reduce work overload. IIE Trans 33(1):29–42
Vilarinho PM, Simaria AS (2002) A two-stage heuristic method for balancing mixed-model assembly lines with parallel workstations. Int J Prod Res 40(6):1405–1420
McMullen PR, Tarasewich P (2003) Using ant techniques to solve the assembly line balancing problem. IIE Trans 35(7):605–617
Yagmahan B (2011) Mixed-model assembly line balancing using a multi-objective ant colony optimization approach. Expert Syst Appl 38(10):12453–12461
Hamta N, Ghomi SMTF, Jolai F, Shirazi MA (2013) A hybrid PSO algorithm for a multi-objective assembly line balancing problem with flexible operation times, sequence-dependent setup times and learning effect. Int J Prod Econ 141(1):99–111
Kucukkoc I, Karaoglan AD, Yaman R (2013) Using response surface design to determine the optimal parameters of genetic algorithm and a case study. Int J Prod Res 51(17):5039–5054
Yano CA, Rachamadugu R (1991) Sequencing to minimize work overload in assembly lines with product options. Manag Sci 37(5):572–586
Kim YK, Hyun CJ, Kim Y (1996) Sequencing in mixed model assembly lines: a genetic algorithm approach. Comput Oper Res 23(12):1131–1145
Zheng YQ, Wang YP, Hu B, Wang YS (2011) A sequencing approach of models in mixed-model assembly lines. Mechanika 17(4):418–422
Bautista J, Cano A (2011) Solving mixed model sequencing problem in assembly lines with serial workstations with work overload minimisation and interruption rules. Eur J Oper Res 210(3):495–513
Zhu XW, Hu SJ, Koren Y, Huang NJ (2012) A complexity model for sequence planning in mixed-model assembly lines. J Manuf Syst 31(2):121–130
Manavizadeh N, Tavakoli L, Rabbani M, Jolai F (2013) A multi-objective mixed-model assembly line sequencing problem in order to minimize total costs in a make-to-order environment, considering order priority. J Manuf Syst 32(1):124–137
Xu S, Li FM (2013) A modified genetic algorithm for sequencing problem in mixed model assembly lines. Adv Mater Res 655–657:1675–1681
Zhang DZ, Kucukkoc I (2013) Balancing Mixed-Model Parallel Two-Sided Assembly Lines. Paper presented at the Proceedings of the International Conference on Industrial Engineering and Systems Management (IEEE-IESM’2013), Rabat, Morocco, October 28 - 30
Boysen N, Fliedner M, Scholl A (2009) Sequencing mixed-model assembly lines: survey, classification and model critique. Eur J Oper Res 192(2):349–373
Kucukkoc I, Zhang DZ (2015) A mathematical model and genetic algorithm based approach for parallel Two-sided assembly line balancing problem. Prod Plan Control. doi:10.1080/09537287.2014.994685
Bartholdi JJ (1993) Balancing 2-sided assembly lines - a case-study. Int J Prod Res 31(10):2447–2461
Kim YK, Kim SJ, Kim JY (2000) Balancing and sequencing mixed-model U-lines with a co-evolutionary algorithm. Prod Plan Control 11(8):754–764
Gökçen H, Agpak K, Benzer R (2006) Balancing of parallel assembly lines. Int J Prod Econ 103(2):600–609
Ozcan U, Gokcen H, Toklu B (2010) Balancing parallel two-sided assembly lines. Int J Prod Res 48(16):4767–4784
Kucukkoc I, Zhang DZ (2013) Balancing Parallel Two-Sided Assembly Lines via a Genetic Algorithm Based Approach. Paper presented at the Proceedings of the 43rd International Conference on Computers and Industrial Engineering (CIE43), The University of Hong Kong, Hong Kong, October 16-18
Kucukkoc I, Zhang DZ (2015) Type-E parallel Two-sided assembly line balancing problem: mathematical model and Ant colony optimisation based approach with optimised parameters. Comput Ind Eng 84:56–69 doi:10.1016/j.cie.2014.12.037
Simaria AS, Vilarinho PM (2009) 2-ANTBAL: An ant colony optimisation algorithm for balancing two-sided assembly lines. Comput Ind Eng 56(2):489–506
Ozcan U, Toklu B (2009) Balancing of mixed-model two-sided assembly lines. Comput Ind Eng 57(1):217–227
Chutima P, Chimklai P (2012) Multi-objective two-sided mixed-model assembly line balancing using particle swarm optimisation with negative knowledge. Comput Ind Eng 62(1):39–55
Ozcan U, Cercioglu H, Gokcen H, Toklu B (2010) Balancing and sequencing of parallel mixed-model assembly lines. Int J Prod Res 48(17):5089–5113
Battaïa O, Dolgui A (2013) A taxonomy of line balancing problems and their solution approaches. Int J Prod Econ 142(2):259–277
Kucukkoc I, Zhang DZ (2014) An Agent Based Ant Colony Optimisation Approach for Mixed-Model Parallel Two-Sided Assembly Line Balancing Problem. Paper presented at the Pre-Prints of the Eighteenth International Working Seminar on Production Economics, Innsbruck, Austria, 24-28 February
Kucukkoc I, Zhang DZ (2014) Mathematical model and agent based solution approach for the simultaneous balancing and sequencing of mixed-model parallel Two-sided assembly lines. Int J Prod Econ 158:314–333
Chryssolouris G (2006) Manufacturing systems: theory and practice (2nd edition). SpringerVerlag, New York
Song BL, Wong WK, Fan JT, Chan SF (2006) A recursive operator allocation approach for assembly line-balancing optimization problem with the consideration of operator efficiency. Comput Ind Eng 51(4):585–608
Corominas A, Pastor R, Plans J (2008) Balancing assembly line with skilled and unskilled workers. Omega Int J Manag Sci 36(6):1126–1132
Manavizadeh N, Hosseini NS, Rabbani M, Jolai F (2013) A simulated annealing algorithm for a mixed model assembly U-line balancing type-I problem considering human efficiency and just-in-time approach. Comput Ind Eng 64(2):669–685
Koltai T, Tatay V (2013) Formulation of workforce skill constraints in assembly line balancing models. Optim Eng 14(4):529–545
Fattahi P, Roshani A, Roshani A (2011) A mathematical model and ant colony algorithm for multi-manned assembly line balancing problem. Int J Adv Manuf Technol 53(1-4):363–378
Jayaswal S, Agarwal P (2014) Balancing U-shaped assembly lines with resource dependent task times: a simulated annealing approach. J Manuf Syst 33(4):522–534
Kara Y, Özgüven C, Yalçın N, Atasagun Y (2011) Balancing straight and U-shaped assembly lines with resource dependent task times. Int J Prod Res 49(21):6387–6405
Gajpal Y, Rajendran C, Ziegler H (2006) An ant colony algorithm for scheduling in flowshops with sequence-dependent setup times of jobs. Int J Adv Manuf Technol 30:416–424
Bard JF, Darel E, Shtub A (1992) An analytic framework for sequencing mixed model assembly lines. Int J Prod Res 30(1):35–48
Costa A, Cappadonna FA, Fichera S (2014) Joint optimization of a flow-shop group scheduling with sequence dependent set-up times and skilled workforce assignment. Int J Prod Res. doi:10.1080/00207543.2014.883469
Ugarte BS, Pellerin R, Artiba A (2011) An improved genetic algorithm approach for on-line optimisation problems. Prod Plan Control 22(8):742–753
Dorigo M, Maniezzo V, Colorni A (1996) Ant system: Optimization by a colony of cooperating agents. IEEE Trans Syst Man Cybern Part B-Cybern 26(1):29–41
Holland JH (1975) Adaptation in natural and artificial systems. MIT Press, Cambridge
Anosike AI, Zhang DZ (2009) An agent-based approach for integrating manufacturing operations. Int J Prod Econ 121(2):333–352
Liang H, Su H, Wang X, Chen MZQ (2014) Swarm aggregations of heterogeneous multi-agent systems. Int J Control 87(12):2594–2603
Cordon O, Herrera F, Stützle T (2002) A review on the Ant colony optimization metaheuristic: basis. Model New Trends Mathware Soft Comput 9(3):141–175
Blum C (2005) Ant colony optimization: Introduction and recent trends. Phys Life Rev 2(4):353–373
Srinivas M, Patnaik LM (1994) Genetic algorithms - a survey. Computer 27(6):17–26
Li YC, Zhao LN, Zhou SJ (2011) Review of genetic algorithm. Adv Mater Res 179–180:365–367
Leitao P (2009) Agent-based distributed manufacturing control: a state-of-the-art survey. Eng Appl Artif Intell 22(7):979–991
Tasan SO, Tunali S (2008) A review of the current applications of genetic algorithms in assembly line balancing. J Intell Manuf 19(1):49–69
Lee ZJ, Su SF, Chuang CC, Liu KH (2008) Genetic algorithm with ant colony optimization (GA-ACO) for multiple sequence alignment. Appl Soft Comput 8(1):55–78
Chen SM, Chien CY (2011) Parallelized genetic ant colony systems for solving the traveling salesman problem. Expert Syst Appl 38(4):3873–3883
Li N, Wang S, Li Y (2011) A Hybrid Approach of GA and ACO for VRP. J Comput Inf Syst 7(13):4939–4946
Arcus A (1966) COMSOAL, A Computer Method of Sequencing Operations for Assembly Lines. Int J Prod Res 4(4):259–277
Helgeson WB, Birnie DP (1961) Assembly line balancing using the ranked positional weight technique. J Ind Eng 12(6):394–398
Talbot FB, Patterson JH (1984) An integer programming algorithm with network cuts for solving the assembly line balancing problem. Manag Sci 30(1):85–99
Baykasoglu A (2006) Multi-rule multi-objective simulated annealing algorithm for straight and U type assembly line balancing problems. J Intell Manuf 17(2):217–232
Arcus AL (1963) An analysis of a computer method of sequencing assembly line operations. Ph.D. Dissertation, University of California, Berkeley, USA
Tonge FM (1960) Summary of a heuristic line balancing procedure. Manag Sci 7(1):21–42
Kim YK, Kim YH, Kim YJ (2000) Two-sided assembly line balancing: a genetic algorithm approach. Prod Plan Control 11(1):44–53
Lee TO, Kim Y, Kim YK (2001) Two-sided assembly line balancing to maximize work relatedness and slackness. Comput Ind Eng 40(3):273–292
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Kucukkoc, I., Zhang, D.Z. Integrating ant colony and genetic algorithms in the balancing and scheduling of complex assembly lines. Int J Adv Manuf Technol 82, 265–285 (2016). https://doi.org/10.1007/s00170-015-7320-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7320-y