Sequencing problem for mixed-model assembly line in a manual boiler plant

This paper discusses a sequencing problem of a mixed-model assembly line (MMAL) in a manual boiler plant in Japan, where is used to assemble a variety of product models with certain level of similarity in operational characteristics. This variety causes workload variance among other problems results in low efficiency and line stops. The evaluation of the product sequencing problem refers to the Goal Cashing Method (GCM) that is being developed by Toyota Motor Company for JIT production. Even if the GCM attempts to minimize the distance between the average and actual workloads for each step of the product sequence, the solution for providing an optimum solution for the entire system is not guaranteed. Hence, this study attempts to find the global optimum for MMAL systems and achieve sufficient balancing of MMAL systems to used genetic algorithm. The results of simulation experiments suggest that the proposed approach is an effective management tool of mixed-model assembly line system.