An Integrated Optimization Method for Setups Planning and Line Balancing of Mixed Model Transfer Lines

In order to solve a class of line setups planning and line balancing problems for mixed model transfer lines with the production of family box-type parts, an integrated optimization method was proposed. Considering the transfer line constraints and precedence relations among operations, cycle time, number of fixture types, balancing ratios, and line smoothing coefficient were taken as optimal objectives. Product proportion coefficient was introduced to the model based on the analysis of the production index of each part with different combinations of setups. Then an improved genetic algorithm was used to optimize the model. Finally, a mixed-model transfer line producing two cylinders was used to demonstrate the validity and efficiency of the proposed method.