A Genetic Algorithm for Flow Shop Scheduling with Assembly Operations to Minimize Makespan

Manufacturing systems, in which, several parts are processed through machining workstations and later assembled to form final products, is common. Though scheduling of such problems are solved using heuristics, available solution approaches can provide solution for only moderate sized problems due to large computation time required. In this work, scheduling approach is developed for such flow-shop manufacturing system having machining workstations followed by assembly workstations. The initial schedule is generated using Disjunctive method and genetic algorithm (GA) is applied further for generating schedule for large sized problems. GA is found to give near optimal solution based on the deviation of makespan from lower bound. The lower bound of makespan of such problem is estimated and percent deviation of makespan from lower bounds is used as a performance measure to evaluate the schedules. Computational experiments are conducted on problems developed using fractional factorial orthogonal array, varying the number of parts per product, number of products, and number of workstations (ranging upto 1,520 number of operations). A statistical analysis indicated the significance of all the three factors considered. It is concluded that GA method can obtain optimal makespan.