Line balancing is aimed at optimum utilization of available workstations so as to complete all tasks in minimum time. This reduces the idle time at each workstation. This is achieved by grouping of tasks without violating cycle time and sequence. Thus, this is a multi-constraint optimization problem.

I am proposing a complete Isight based solution to end user for line balancing where the user would need to just specify the line details into a .zmf file and execute the .zmf file to get Balanced Line.   

A detailed process flow of this Isight Solution has been presented below:

The details of the above process flow to implement Isight Solution have been presented in attached ppt.

Above work-flow explains use of Excel component as well as Optimization component to arrive at minimum number of work stations. Excel template is used to feed the input data like Time, Initial workstations, and immediate predecessor workstation for each activity. Optimization component provides an algorithm to drive the problem defined in Excel component to minimize the work-stations. Constraints are defined using prologue/epilogue.

Validation of the solution:

Example 1:

Above work-flow has been validated for a small problem of 6 activities to reduce the assigned workstations to 3.  

Reference 1: Chong K. E., Omar M. K., and Bakar N. A., “Solving Assembly Line Balancing Problem using Genetic Algorithm with Heuristics-Treated Initial Population”, Proceedings of the World Congress on Engineering 2008 Vol II.

Example 2

A medium sized problem of 36 activities has been solved to reduce the assigned workstations to 12.

Reference 2:Pornsing C., and Wattanasungsuit A., “Genetic algorithm approach to the quality-related assembly line balancing problem", Proceedings of the International MultiConference of Engineers and Computer Scientists, 2008, Vol II.

I would like to thank UKE Yogesh, WALVEKAR Kedar, CHITNIS Mahesh, BIRAJDAR Nilesh, KULKARNI Ashish & NAGOSE Rajesh for providing valuable input and directions for completion of this project.