Implementing Changes in the Balancing of Assembly Lines: a Sequencing Problem Addressed by MILP

The productivity levels of an assembly line are intimately tied to the balancing quality of the workstations. Several optimization methods focus on finding the best balancing configuration for productive lines, but very few is published about implementing these solutions. When a line’s actual configuration greatly differs from the new project, a scheduling of stepwise interventions can increase the implementation viability. In this paper, a mixed-integer linear programming model for dividing the implementation in feasible steps is presented. An integrated balancing and sequencing model is used to minimize the effort or cost of implementations. Case studies are presented to illustrate industrial circumstances in which implementations have to be performed by steps and the effect on the multi-period planning. A stepwise implementation divides the changes in minimal packages, increasing the viability and applicability of (re) balancing projects.