Achieving shojinka by integrated balancing of multiple straight lines with resource dependent task times

Abstract

The concept of Shojinka, which is an important element of Just in Time production system, is attaining flexibility on the number of workers in a workshop due to demand variations. Even though Just in Time production system adopts U-shaped line layout, traditional straight lines can be combined and balanced in an integrated manner to obtain the advantages of Shojinka. In this case, the problem, which is called Integrated Balancing of Multiple Straight Lines, arises. On the other hand, the basic assumption of assembly line balancing is that every task’s time is fixed. However, in practice, different resource alternatives such as equipment or assistant worker may be available to process a task with different times. The problem in this case is to assign tasks and resources to stations that minimise total cost. In this study, a binary integer mathematical model is presented for integrated balancing of multiple straight lines, assuming that task times are resource dependent. The proposed model is illustrated and validated using several examples. An experimental analysis is also conducted to emphasize the advantages of the integrated balancing concept, compared to the situation in which the lines are balanced independent from each other. The experimental results show that, when multiple straight assembly lines are balanced in an integrated manner with resource dependent task times, an average total cost improvement of 23.105% can be obtained compared to the independent balances of the lines. This is a significant improvement that emphasizes the importance of balancing multiple straight lines in an integrated manner, to take the advantages of shojinka and to adhere to the main philosophy of Just in Time. © Springer Nature Switzerland AG 2019.