Line balancing in a just-in-time production environment: balancing multiple U-lines

The introduction of multiple, independent production lines has helped many firms to increase their production flexibility, provide for redundancy when equipment breaks down, reduce idle time and labor costs, and achieve many other benefits. This paper introduces and formalizes the multiple U-line balancing problem. Optimal solution methodologies are provided for Type I (minimize the number of stations for a given cycle time), Type II (minimize the cycle time for a given number of stations), and cost-minimization line-balancing problems. A branch-and-bound algorithm is also developed for the situation in which equipment requirements are dependent on the line configuration and the task assignment to stations. Computational results indicate that the greatest benefit of exploiting multiple lines occurs for smaller cycle-time problems that require higher output.