Balancing of Parallel U-Shaped Assembly Lines with Crossover Points

This research introduces parallel U-shaped assembly lines with crossover points. Crossover points are connecting points between two parallel U-shaped lines making the lines interdependent. The assembly lines can be employed to manufacture a variety of products belonging to the same product family. This is achieved by utilizing the concepts of crossover points, multi-line stations, and regular stations. The binary programming formulation presented in this research can be employed for any scenario (e.g. task times, cycle times, and the number of tasks) in the configuration that includes a crossover point. The comparison of numerical problem solutions based on the proposed heuristic approach with the traditional approach highlights the possible reduction in the quantity of workers required. The conclusion from this research is that a wider variety of products can be manufactured at the same capital expense using parallel U-shaped assembly lines with crossover points, leading to a reduction in the total number of workers.