A novel integer programming formulation with logic cuts for the U-shaped assembly line balancing problem

Abstract

U-shaped assembly lines are regarded as an efficient configuration in Just-In-Time manufacturing. Balancing the workload in these lines is an unsolved problem that attracted significant research within the past two decades. We present a novel integer programming formulation for U-shaped line balancing problems, where cycle time, the interval between two consecutive outputs, is known and the aim is to minimize the number of workstations. To enhance the efficiency of the LP relaxation of the new formulation, we present three types of logic cuts (assignable-station-cuts, task-assignment-cuts and knapsack-cuts) that exploit the inherent logic of the problem structure. The new formulation and logic cuts are tested on an extensive set of benchmark problems to provide a comparative analysis with the existing models in the literature. The results show that our novel formulation augmented by assignable-station-cuts is significantly better than the previous formulations.