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This paper aims to bridge the gap between theory and practice by addressing a real-world assembly line balancing problem (ALBP), where task times are stochastic and there are zoning constraints in addition to the commonly known ALBP constraints. A mixed integer programming (MIP) model is proposed for each of the straight and U-shaped assembly line configurations. The primary objective in both cases is to minimize the number of stations; minimizing the maximum of stations’ meantime; and the stations’ time variance is considered as secondary objectives. Four different scenarios are discussed for each model, with differences in the objective function. The models are validated by solving a real case taken from an automobile manufacturing company and some standard test problems available in this paper. The results indicate that both models are able to provide optimum solutions for problems of different sizes. The technique for order preference by similarity to ideal solution (TOPSIS) is used to create reliable comparisons of the different scenarios and valid analysis of the results. Finally, some insights regarding the selection of straight and U-shaped layouts are provided.

An Optimization Model for Balancing Assembly Lines With Stochastic Task Times and Zoning Constraints