Application of the results of simple assembly line balancing models in practice: the case of a bicycle manufacturer

Abstract

The objective of assembly line balancing (ALB) is the allocation of tasks to workstations of continuous production lines in order to minimise operating cost or other cycle time-related management criteria. As a consequence of the development of computer technology, mathematical programming models of practical-sized ALB problems can be solved by commercial optimisation software very efficiently. Therefore, the focus of research in ALB can be shifted to practice-driven model formulation and to the investigation of new areas of application. The objective of this paper is to show how cycle-time related operations management decisions can be supported with quick solution of ALB models through the case of a bicycle assembly process. Practical ALB problems related to workforce skill and to production quantity changes are presented and management implications of the results are explained.

Keywords:

• assembly line balancing
• mathematical programming
• operations management
• worker skill
• bicycle manufacturing
• case study

Acknowledgement

The authors wish to acknowledge the invaluable support of Olympia Bicycle Ltd., by providing all the necessary information for this research.