
 
problem has been receiving attention of researchers 
since it has been first identified by Capacho & 
Pastor (2005), However, all of the researchers 
considered only single model with serial lines such 
as Capacho & Pastor (2006, 2008), and Scholl et al. 
(2009). In this study, we considered U-shaped 
assembly line balancing models with alternative 
subassembly graphs (uALB/sb). The problem under 
consideration contains two kinds of special issues, 
i.e. the selection of a suitable subassembly graph 
among alternatives and the balancing according to 
the operational precedence constrained among the 
tasks in the selected subassembly graph.  
Traditionally to solve these kinds of u-ALB/sb 
problems, researchers first tries to identify the best 
alternative in the form of one precedence diagram 
and finally balance this problem using only this 
precedence diagram.  However, most of the time, 
researchers are giving the utmost importance to the 
balancing rather than the selection of alternatives. 
Particularly, the disjunctive relationship between 
these two problems is often neglected and they are 
solved separately in a hierarchical manner. 
Nevertheless, by using the traditional hierarchical 
approach, the u-ALB/sb problem can lose its 
integrity since the researchers are eliminating some 
features of the whole problem before balancing 
procedure.   
To maintain the integrity of the u-ALB/sb 
problem, in this study, an integrated monolithic 
approach, which considers selection together with 
balancing, is proposed. Particularly, a multi-stage 
decision based genetic algorithm (mdGA) approach 
is constructed in order to consider it as an exclusive 
problem while using a specific decoding procedure. 
The rest of the paper is organized as follows; In 
Section 2, the background information on the main 
features of u-ALB/sb are introduced. In Section 3, 
overall methodology of the proposed mdGA 
approach and its general features are discussed in 
detail. In Section 4, in order to evaluate the 
performance, the proposed mdGA approach is 
demonstrated on some problem instances, and the 
experimental results are analyzed. Finally, the 
concluding remarks and future research directions 
are given in the last section. 
2 BALANCING U-SHAPED 
ASSEMBLY LINES WITH 
ALTERNATIVE SUBASSEMBLY 
GRAPHS 
The  assembly  line  balancing  problems  are usually 
represented with precedence relations, which can be 
transformed into a more visual form as precedence 
diagrams. Precedence diagrams only model 
conjunctions (AND relations), not disjunctions (OR 
relations). However, in real-life, we usually come 
across assembly line balancing problems with 
alternative subassembly graphs. In this section, we 
considered uALB models with alternative 
subassembly graphs (uALB/sb). The uALB is a 
generalization of assembly line balancing problems 
and hence belongs to the class of NP-hard problems. 
Hence its decision version uALB/sb is NP-complete. 
As a disjunctive network optimization problem, in 
uALB, each subassembly graph represents 
subassembly, which is the alternative way for 
performing a subset of task or tasks and each node 
represents the tasks of a subassembly. The uALB/sb 
model consists of i=0,1,…,  I+1 subassemblies and 
the precedence relations between each subassembly 
are taken into consideration according to the 
network structure. In each subassembly i, there are 
k=0,1,…,  K+1 alternative  ways to perform that 
subassembly. Fig.1 illustrates the conceptual 
network for assembly line balancing problem with 
alternative subassembly graphs.  
In each alternative subassembly k, there are 
j=0,1,…, J+1 tasks with precedence relations, where 
p
ikj
 denotes the variable processing time of  task j in 
alternative  k  of subassembly i. Particularly, the 
detailed concepts of subassembly graphs and task 
are given in Fig.2. In this model, the activities are 
interrelated by two kinds of constraints; the 
precedence constraints which are known from 
traditional uALB, force a task no to be started before 
all its predecessors have been finished and the new 
constraints force a subassembly no to be started 
before all its predecessors have been finished.  
Specifically, the uALB/sb model considered in 
this study can be defined by the following 
assumptions:   
A1.  The problem consists of multiple 
subassemblies. 
A2.  There exists alternative ways to perform 
each subassembly.  
A3.  Each subassembly alternative contains 
number of tasks with known processing 
time  
A4.  The assembly line is used to assemble 
one homogeneous product in mass 
quantities.  
A5.  The line is U-shaped, paced line with 
fixed cycle time and there are no feeder 
lines.  
MULTI-STAGE DECISION BASED APPROACH FOR BALANCING BI-OBJECTIVE U-SHAPED ASSEMBLY
LINES WITH ALTERNATIVE SUBASSEMBLY GRAPHS
335