Mixed-integer linear programming models for the type-II resource-constrained assembly line balancing problem

Abstract

Purpose Resource-constrained assembly lines are widely found in industries that manufacture complex products. In such lines, tasks may require specific resources to be processed. Therefore, decisions on which tasks and resources will be assigned to each station must be made. When the number of available stations is fixed, the problem’s main goal becomes the minimisation of cycle time (type-II version). This paper aims to explore this variant of the problem that lacks investigation in the literature. Design/methodology/approach In this paper, the authors propose mixed-integer linear programming (MILP) models to minimise cycle time in resource-constrained assembly lines, given a limited number of stations and resources. Dedicated and alternative resource types for tasks are considered in different scenarios. Findings Besides, past modelling decisions and assumptions are questioned. The authors discuss how they were leading to suboptimal solutions and offer a rectification. Practical implications The proposed models and data set fulfil more practical concerns by taking into account characteristics found in real-world assembly lines. Originality/value The proposed MILP models are applied to an existing data set, results are compared against a constraint programming model, and new optimal solutions are obtained. Moreover, a data set extension is proposed due to the simplicity of the current one and instances up to 70 tasks are optimally solved.