Multimanned assembly line balancing problem: A case study in backhoe loader manufacturer

When large quantities are ordered for long periods for a final product, it is more economical and logical for firms to make a special layout for this product. Assembly lines are a special form of placement systems according to the product. In this system, tasks are the smallest and indivisible state of a job. In the formation of the system, the tasks are sequentially arranged in order according to the relationship of precedence between them. As a result, assembly lines are the system in which raw materials or semi-finished products leave the end of the line as final products. The main purpose of an assembly line is to meet the demands of large quantities of products in the most economical and fast manner. The assembly lines of high volume products such as buses, trucks, and helicopters differ from traditional lines examined in the literature. In the production processes of these products, there are long working times and a great number of tasks. Assembly lines with 1 worker (traditional assembly lines) or 2 workers (two-sided assembly lines) at each workstation are not suitable for this type of product. Multi-manned assembly lines allow workers to perform in more than one and varying numbers at each workstation. At this point, the assembly process can be performed with fewer workstations and lower cycle time. There is not much research on a multi-manned assembly line balancing problem. However, research on the multi-manned assembly lines has accelerated in the recent years. In this study, a mathematical model and heuristic algorithm were developed for balancing the multi-manned assembly line of a fabrication of assembly, which unlike traditional assembly line balancing. This study presents heuristic algorithm which is based on COMSOAL method to balance the assembly line. This model aims to minimize the workstation number. Thanks to this model, a reasonable workstation gain was achieved in the assembly line of the manufacturing factory. In order to meet the needs of the factory, the model was also run according to different production speeds.