On a learning precedence graph concept for the automotive industry

Assembly line balancing problems (ALBP) consist in assigning the total workload for manufacturing a product to stations of an assembly line as typically applied in automotive industry. The assignment of tasks to stations is due to restrictions which can be expressed in a precedence graph. However, (automotive) manufacturers usually do not have sufficient information on their precedence graphs. As a consequence, the elaborate solution procedures for different versions of ALBP developed by more than 50 years of intensive research are often not applicable in practice. Unfortunately, the known approaches for precedence graph generation are not suitable for the conditions in the automotive industry. Therefore, we describe a new graph generation approach that is based on learning from past feasible production sequences and forms a sufficient precedence graph that guarantees feasible line balances. Computational experiments indicate that the proposed procedure is able to approximate the real precedence graph sufficiently well to detect optimal or nearly optimal solutions for a well-known benchmark data set. Even for additional large instances with up to 1,000 tasks, considerable improvements of line balances are possible. Thus, the new approach seems to be a major step to close the gap between theoretical line balancing research and practice of assembly line planning. (C) 2011 Elsevier B.V. All rights reserved.