Improving assembly line efficiency: A dynamic programming-heuristic approach

Abstract Many existing heuristic or algorithmic techniques that address the problem of balancing an assembly line build upon the classical approach to balancing, i.e. the solution procedure requires the “proper organization of work elements.” In some assembly operations, however, particularly an existing operation, a classical-based balancing system may be undesirable. If physical and economic constraints dictate the structure of a line or if excessive delivery delays, backlogs, and/or lost business can result from stopping a line to achieve the proper organization of work elements, then an “unbalanced” line may be a desirable alternative. This is particularly true if the efficiency of the unbalanced line can be improved, i.e. if lost time due to the imbalance condition can be avoided. The goal of this research was to show that a dynamic programming-heuristic procedure can be used to improve the efficiency of an unbalanced line. Specifically, the objective was to demonstrate that an “optimal” allocation of manpower can be made such that an existing flowrate can be achieved with reduced manpower requirements. Reduced in-process storage can also result from use of the technique.