AGE AND GENDER BASED WORKLOAD CONSTRAINT FOR ASSEMBLY LINE WORKER ASSIGNMENT AND BALANCING PROBLEM IN A TEXTILE FIRM
DOI:
https://doi.org/10.23055/ijietap.2018.25.1.2961Keywords:
Human factors, assembly line worker assignment and balancing problem, linear programming, physical workload capacityAbstract
This paper investigates Assembly Line Worker Assignment and Balancing Problem (ALWABP), focusing specifically on productive workload differences due to age and gender of workers, to minimize the number of workstations. Most of the published papers on assembly line balancing problems (ALBP) are focused only on the task processing times. However, this may cause an overload in work assignments for certain workers. A work-overload may cause fatigue and thus lead to a decrease in line efficiency, and thus factory productivity, and also an increase in quality problems and work-related injuries. To avoid or ameliorate these problems, this paper assigns tasks among workstations without exceeding the cycle time or the age and gender-adjusted physical workload capacity (PWLC). We propose a regression model to determine age and gender-based PWLC. Six different age categories are analyzed to show the impacts of age and gender on PWLC. We propose a binary (0-1) integer linear programming (BILP) for ALWABP, where age and gender-adjusted PWLC is considered. Efficiency of the model is shown on test problems and a real-life application in a textile firm. An ALWABP is considered taking into account the processing times and physical workloads for an assembly line in the textile firm with 53 tasks. The numbers of stations for ALWABP without and with physical workload in the textile firm are 5 and 6, respectively. All workstations are balanced in terms of physical workload and processing times. The results also show that advancing average age increases the number of stations (NS), and this situation triggers a reduction in line efficiency (LE) and PWLC utilization ratio.
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