Re-balancing problem for assembly lines: new mathematical model and exact solution method

Purpose – The purpose of this study is to develop a new mathematical model and an exact solution method for an assembly line rebalancing problem. When an existing assembly line has to be adapted to a new production context, the line balancing, resources allocation and component management solutions have to be revised. The objective is to minimize the number of modifications to be done in the initial line in order to reduce the time and investment needed to meet new production requirements. The proposed model is evaluated via a computational experiment. The obtained results the efficacy of the proposed method. Design/methodology/approach – This paper develops a new mathematical model and an exact solution method for an assembly line rebalancing problem with the objective to minimize the number of modifications to be done in the initial line to reduce the time and investments needed to meet new production requirements. Findings – The computational experiments show the efficacy of the proposed method. Originality/value – These reconfiguration costs were analysed for different part-feeding policies that can be adopted in an assembly line.