Assembly line balancing and activity scheduling for customised products manufacturing

Nowadays, end customers require personalized products to match their specific needs. Thus, production systems must be extremely flexible. Companies typically exploit assembly lines to manufacture produces in great volumes. The development of assembly lines distinguished by mixed or multi models increases their flexibility concerning the number of product variants able to be manufactured. However, few scientific contributions deal with customizable products, i.e., produces which can be designed and ordered requiring or not a large set of available accessories. This manuscript proposes an original two-step procedure to deal with the multi-manned assembly lines for customized product manufacturing. The first step of the procedure groups the accessories together in clusters according to a specific similarity index. The accessories belonging to a cluster are typically requested together by customers and necessitate a significant mounting time. Thus, this procedure aims to split accessories belonging to the same cluster to different assembly operators avoiding their overloads. The second procedure step consists of an innovative optimization model which defines tasks and accessory assignment to operators. Furthermore, the developed model defines the activity time schedule in compliance with the task precedencies maximizing the operator workload balance. An industrial case study is adopted to test and validate the proposed procedure. The obtained results suggest superior balancing of such assembly lines, with an average worker utilization rate greater than 90%. Furthermore, in the worst case scenario in terms of customer accessories requirement, just 4 line operators out of 16 are distinguished by a maximum workload greater than the cycle time.