Minimising the Cycle Time with Assembly Line Balancing and Worker Assignment: A Case Study in a Medical Device Manufacturer Company

Abstract

In this research, we considered the mixed-model assembly line balancing and worker assignment problems of a medical device manufacturer in Türkiye. We combined these problems into a single integer programming model where multiple types of products can be assembled simultaneously on a single assembly line, and workers are assigned to workstations based on their abilities while ensuring the balance and efficiency of the assembly line. Our proposed approach seeks to minimise the cycle time and ability-based assignment costs on the assembly line. We used the Gurobi solver to find the optimal solution for the proposed problem. Our approach provides higher efficiency and results in a 76% increase in productivity without requiring additional work hours or workers. © 2025 Published by ISRES Publishing.