Abstract
In order to solve the simple assembly line balancing problem of type 1, an improved immune algorithm is proposed. Compared with the basic immune algorithm: (1) The similarity formula between any two antibodies is simplified in the improved immune algorithm. (2) Introducing immune adjustment, vaccine extraction, vaccination, and immune selection, the improved immune algorithm prevents population degradation. The validity of the proposed improved immune algorithm is tested by means of two computational examples with reference instances, and the results show that the proposed improved immune algorithm is an efficient approach to solve the simple assembly line balancing problem of type 1.
Introduction
The assembly line balancing problem (ALBP) is to determine the assignment of the tasks to an ordered sequence of stations such that each task is assigned to exactly one station, no precedence constraint is violated, and some selected performance measure is optimized. 1 The ALBP is an important issue of the manufacturing field, and it directly affects the production efficiency and the utilization of manufacturing resources.
The ALBP was first mathematically formulated by Salveson 2 in 1955. Because of the importance of the ALBP (especially in the manufacturing industry), it has attracted interests from a lot of scholars and engineers in the past 60 years.
Generally speaking, the ALBP is divided into two classes: simple assembly line balancing problem (SALBP) and generalized assembly line balancing problem (GALBP). The SALBP means that a single product is produced, the set of tasks are of deterministic operation times, and the set of workstations are arranged in a straight line. Meanwhile, GALBP includes all of the problems that do not belong to the SALBP class, such as mixed-model or multimodel line, parallel stations, U-shaped or two-sided lines, stochastic task times, etc. According to the objectives, the SALBP can be categorized into three types: (1) simple assembly line balancing problem of type 1 (SALBP-1): minimize the number of stations for a given cycle time which is mainly used in the design and installation phase of the assembly line. (2) SALBP-2: minimize the cycle time given the number of workstations which is mainly used to optimize and adjust the existing assembly line. (3) SALBP-E: balance the workload while both the workstation and the cycle time are optimized.
In this paper, only SALBP-1 will be considered, because it is widely used in industry to reduce number of workstations/machines/workers. These reductions lead to decrease production cost and improve the cost competitiveness of the plant. 3
The remainder of the paper is organized into five sections, i.e. literature review, mathematical model of SALBP-1, the improved immune algorithm (IIA), case study and discussion, and conclusions.
In summary, the methods to solve SALBP-1 discussed in literatures can be roughly classified into three kinds: exact method, heuristic approach, and artificial intelligence method.
Sprecher 4 presented a branch-and-bound algorithm for solving SALBP-1. The computational results indicated that the algorithm can compete with the best algorithms currently available for solving SALBP-1. Easton et al. 5 presented two network-based algorithms for solving the SALBP-1. Computational tests indicated that these algorithms were more efficient than previous network-based methods (including dynamic programming methods) and favourably compare with branch-and-bound methods. Peeters and Degraeve 6 presented a new lower bound, namely the LP relaxation of an integer programming formulation based on Dantzig–Wolfe decomposition to solve SALBP-1. Computational results showed that the lower bound was equal to the best-known objective function value for the majority of the instances. Moreover, the new LP-based lower bound was able to prove optimality for an open problem. Liu et al. 7 presented a branch-and-bound algorithm to solve SALBP-1. The proposed algorithms consisted of a constructive and two destructive algorithms. The computational results showed that the proposed algorithms are efficient. Bautista and Pereira 8 presented a bounded dynamic programming to solve SALBP-1. The results obtained by the procedure showed that the implementation was capable of obtaining an optimal solution of 267 out of the 269 instances found in the literature. As well, it also found the best-known solution for another of the instances. Sewell and Pereira 9 presented a branch, bound, and remember algorithm for solving SALBP-1. The algorithm combined a variety of existing methods to create a novel approach that was computationally superior to all existing exact algorithms reported in the literature. In particular, for 269 known benchmark problems, the algorithm successively found the best solutions and proved their optimality for all these problems, typically in a fraction of a second. Vila and Pereira 10 presented a new exact algorithm for solving SALBP-1. The algorithm was a station-oriented bidirectional branch-and-bound procedure based on a new enumeration strategy that explores the feasible solutions tree in a non-decreasing idle time order. The tests showed that the proposed algorithm outperformed the best existing exact algorithm for solving SALBP-1, verifying optimality for 264 of the 269 benchmark instances.
Because the SALBP-1 belongs to NP-hard class of combinatorial optimization problems, the exact methods are computationally inefficient in solving large-scale problem, many researchers turn their interests to develop efficient heuristic approaches to solve SALBP-1.
Helgeson and Birnie 11 presented a method called the ranked positional weight technique to solve SALBP-1. Hoffmann 12 presented a procedure by applying the FORTRAN program to solve SALBP-1. The procedure led to optimal line balances by operation on a matrix of zeros and ones called a ‘Precedence Matrix’. Hackman et al. 13 proposed a simple, fast, and effective heuristic named immediate update first-fit for the SALBP-1. The algorithm introduced heuristic fathoming as a technique for reducing the size of the branch-and-bound tree. Fleszar and Hindi 14 presented a new heuristic algorithm and new reduction techniques for the SALBP-1. The new heuristic is based on the well known Hoffmann heuristic and builds solutions from both sides of the precedence network to choose the best. The computational efficiency enables it to arrive at optimal or near-optimal solutions for large-scale problem instances in less than 2 s of computing time on a PC. Kilincci and Bayhan 15 developed a heuristic algorithm, P-in, based on P-invariants of PNs to solve SALBP-1. The algorithm was coded in MATLAB, and its efficiency was tested on Talbot’s and Hoffmann’s benchmark datasets according to some performance measures and classifications. Yeh and Kao 16 proposed a new efficient heuristic, based on a recent bidirectional approach and the famous critical path method widely used in project management, to resolve the issue of task assignment for SALBP-1. The effectiveness of the proposed heuristic algorithm was verified by sample problems. Otto and Otto 17 provided recommendations for ad hoc, i.e. without pretests, construction of priority rules and illustrated their effectiveness on the example of ALBP with resource constraints. The authors showed in a split second priority rules achieve much better results than 20–100s of an exact algorithm or a metaheuristic, and may reduce the warming-up phase of algorithms significantly.
Because of the differences among the SALBP such as the numbers of tasks, precedence relations between tasks, so far there hasn’t been a heuristic rule to ensure that all of SALBP-1 can get the optimal solution.
In recent years, numerous researchers have employed artificial intelligence method to solve SALBP-1.
Ponnambalam et al. 18 proposed a multi-objective genetic algorithm to solve SALBP-1. It was found that the proposed genetic algorithm performs better in all the performance measures than the heuristics. However, the execution time for the GA was longer, because the GA searches for global optimal solutions with more iterations. In order to solve the deterministic and single-model ALB problem, Sabuncuoglu et al. 1 developed a new GA with a special chromosome structure that is partitioned dynamically through the evolution process. The results of extensive computational experiments indicated that the proposed GA approach outperforms the well known heuristics in the literature. Goncalves and De Almeida 19 presented a hybrid genetic algorithm for the SALBP-1. The chromosome representation of the problem was based on random keys and the assignment of the operations to the workstations was based on a heuristic priority rule. The computation results validated the effectiveness of the algorithm. Gonçalves and De Almeida 20 presented a new hybrid genetic algorithm for the SALBP-1. The approach combined a heuristic priority rule, a local search procedure, and a genetic algorithm. The genetic algorithm used a random keys alphabet, an elitist selection, and a parameterized uniform crossover. The computation results validated the effectiveness of the algorithm. Yu and Yin 21 presented an adaptive genetic algorithm to solve SALBP-1. The computational results demonstrated that the proposed adaptive genetic algorithm is an effective algorithm. Yolmeh and Kianfar 22 proposed a hybrid genetic algorithm to solve SALBP-1. The computational results validated the effectiveness of the algorithm. Blum 23 proposed a hybrid ant colony optimization approach called Beam-ACO for the SALBP-1. The results showed that Beam-ACO is a state-of-the-art metaheuristic for the SALBP-1. Sulaiman et al. 24 presented an approach based on the ant colony optimization technique to address the SALBP-1. It introduced an approach to dynamically assign the value of priority rule or heuristic information during the task selection phase by allowing the ant to look forward its direct successors during the consideration in selecting a task to be assigned into a workstation. The computation results validated its effectiveness. Dou et al. 25 proposed a direct discrete particle swarm algorithms (DDPSA) to solve SALBP-1. In the presented DDPSA, a particle is a permutation of N integers that represents the feasible task sequence directly, and a new multi-fragment crossover is proposed to update the particle and maintain the feasibility of the task sequence. In order to avoid the stagnation of search in local optimum, the fragment mutation is embedded into the DDPSA. The results showed that the DDPSA is effective and powerful for the SALBP-1. Lapierre et al. 26 proposed a novel tabu search algorithm for solving both SALBP-1 and non-standard versions of this problem coming from real life applications. Computational results on both showed that the method was efficient. Guden and Meral 27 proposed an adaptive simulated annealing method to solve the real life SALBP-1 of a dishwasher producer which consisted of approximately 300 tasks, 400 precedence relations per product model. Performance of the algorithm was tested on several problem instances from the literature and found to be satisfactory. Then it was used to solve the real life problem instance considered and a better solution than the current one was obtained.
Some more detailed literature review of the ALBP can be found in the literature.28–33
The remainder of the paper is as follows: The mathematical model of SALBP-1 is provided. The next section presents the IIA for finding the solution. Three computational examples are used to test the proposed IIA. Conclusions are given in the final section.
Mathematical model of SALBP-1
The notations that will be used throughout the paper are described in the Appendix.
Mathematical formulation
The mathematical formulation is as follows.
Objective function
Generally speaking, the objective function of SALBP-1 is to minimize the number of the workstations, i.e.
The smooth index is adopted as the auxiliary objective function named f2, i.e.
So, the objective function is
Constraint conditions
Equation (2) ensures that every task is assigned to one and only one workstation. Constraint (3) defines precedence relationships between tasks i and j. Constraint (4) ensures that the processing time of every workstation has not exceeded the cycle time. Constraint (5) defines the variable domains.
The IIA
Affinity
In the immune optimization algorithm, the antigens correspond to optimization problems and the antigens are usually objective function, and the antibodies correspond to the optimum solution to the problems.
The affinity between antigen and antibody corresponds to the matching between feasible solution and optimum solution which is called antibody fitness. The larger the antibody fitness is, the closer the feasible solution is to the optimum solution. The antibody fitness is calculated as shown in equation (1).
Affinity between antibodies corresponds to the similar degree between feasible solutions which is called similarity. The larger the similarity is, the more similar the feasible solutions are.
Suppose M antibodies, each antibody is composed of N genes, r species can be chosen in each genetic locus ranging from k1 to kr, i(j) represents the values of antibody i on the jth genetic locus (Figure 1).
Allele schematic drawing.
Obviously, i(j)
The average information entropy of the M antibodies is defined as follows
Therefore, equation (8) can be derived from equations (6) and (7)
If (1) the value of the jth genetic locus is ki, and (2) the frequency that ki occurs is
The similarity
According to equation (8),
According to equations (9) and (10),
Concentration
Antibody concentration ci means the numbers of the antibodies similar to antibody i divided by the antibody population M, and it is defined as follows
Antibody survival expectancy
In order to preserve the diversity of the antibody population and avoid premature convergence, antibody survival expectancy is used to promote and inhibit the antibody population, and the antibody survival expectancy is defined as follows
Obviously, the antibody with low fitness or low concentration will be promoted, and that with high fitness or high concentration will be inhibited. As a result, this forms a new diversity keeping strategy.
Memory vault
Memory vault is used to save the excellent antibody and the original memory vault is usually designed by the engineers.
The IIA algorithm flow
Step 1. Setup parameters
M: the population size. L: the number of immune adjustment. Pi: the immune vaccination probability. λ: the similarity threshold. MNI: the maximum number of iterations
Step 2. Initialize
The M individuals are generated randomly. But it does not guarantee that all of the individuals meet the constraint (3). If an individual doesn’t meet the constraint (3), then the individual is invalid. In consideration of this, the following algorithm 1 presents the steps on how to convert any individual to meet the constraint (3), i.e. to meet the assembly precedence matrix. Convert any individual to meet the assembly precedence matrix Notations: n is the number of tasks. A represents any an individual, and A is a matrix with n rows and one column. 1: for i = 1: n − 1 2: If 3: end 4: endAlgorithm 1
Step 3. Immune adjustment
The diversity of antibody is the important characteristic of the immune system. The solving steps of immune adjustment are described as follows.
Generating randomly L individuals; Converting the L individuals to meet the constraint (3) according to algorithm 1; Calculating antibody survival expectancy ei according to formulas (13), and selecting M individuals as the (t + 1)th generation population
Step 4. Immunization
Immunization mainly includes two stages: vaccine extraction and vaccination.
Step 4.1 Extracting the vaccine
Because the global optimal individual Pg is close to the global optimal solution in the process of IIA, Pg is chosen as vaccine.
Step 4.2 Vaccination
Let
First, M1 individuals are selected randomly as Select a positive integer randomly as the crossover point from 1 to Maintain the left segment of the crossover point of parent, in vaccine delete these genes which are the same as those in the left segment of the crossover point of parent, maintain the original order of the remaining genes of vaccine to replace the right segment of the crossover point of parent, i.e. offspring is generated. The process of single point crossover.

After the immune vaccination operation,
Step 5. Immune selection
The principle of immune selection is as follows.
If
If
Based on the above principle, M1 individuals are selected from
Step 6. Update the memory vault
The objective function of all the
Step 7. Termination condition
Generally speaking, the algorithm is stopped when it satisfies one of the following three conditions:
The number of iterations reaches a predefined number; The objective fitness of the best individual reaches a predefined threshold; The objective fitness of the best individual converges with the increase of iterations, so does the average value of the population’s objective fitness.
In this paper, condition 1 is selected as the termination condition of the IIA. Once condition 1 is satisfies, then the IIA goes to Step 8; otherwise, it goes to Step 3.
Step 8. Output
Output the best solution.
The pseudo-code of the IIA is shown in Figure 3.
Pseudo-code of the IIA. IIA: improved immune algorithm.
Case study
The IIA was coded in MATLAB and the experimental results were obtained on a PC with 2 GHz CPU and 3 GB RAM. Referring to Goncalves and Almeida 34 and Zhang et al., 35 the IIA had the following configuration:
The population size M equals the number of tasks in the problem.
The number of immune adjustment L is equal to
The immune vaccination probability Pi is equal to 0.7.
The similarity threshold
The maximum number of iterations MNI is equal to 3*M.
Example 1
Experiment results for four datasets.
DPSO: discrete particle swarm optimization algorithm; IIA: improved immune algorithm.
As can be observed in Table 1, the IIA produces the best number of stations that is as good as the DPSO. Comparing the generation number of the best solution, the IIA obtains the optimum faster than the DPSO when the name is Sawyer, the number of tasks is 30, and the cycle time is 36. The comparison results show that the IIA is effective and efficient for SALBP-1.
Example 2
The second set of test problems are 25 classes of instances of SALBP-1 selected from Yu and Yin.
21
The cycle time is 30 units and the network is shown in Figure 4.
Assembly precedence diagram for 25 tasks.
Comparison of the assembly balancing result.
where
AGA: adaptive genetic algorithm; IIA: improved immune algorithm.
It can be seen that the number of workstations calculated by IIA is the same as that by AGA, but the smooth index calculated by IiA is smaller than that by AGA. The smaller smooth index means that the processing time among workstations is closer, and this will increase the coefficient of utilization of workers and equipment. Obviously, the proposed IIA can produce better balancing effect than AGA.
Conclusions
In this research, the IIA is proposed to solve the SALBP-1 which aims to minimize the number of workstations and workstation load for a given cycle time of assembly line. The similarity formula between any two antibodies is simplified in the process of immune algorithm. The validity of the proposed IIA is tested by means of three computational examples with reference instances, and the results show that the proposed IIA is an efficient approach to solve the SALBP-1.
In the future, I plan to extend the IIA to solve other types ALBPs, such as two-sided assembly lines. Other artificial intelligence algorithm should be developed to solve the SALBP-1, such as chaotic water cycle algorithm, 37 chaotic artificial immune system optimization algorithm, 38 brainstorm optimization algorithm, 39 etc.
Footnotes
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.
Funding
The author(s) received no financial support for the research, authorship, and/or publication of this article.
