Incorporating Worker Heterogeneity in Flexible Flow Shop Environment

Abstract

We study the flexible flow shop scheduling problem with the heterogeneous worker assignment. In many real-life manufacturing systems with flow shop environments, one of the fundamental scheduling challenges that needs to be addressed is job sequences across multiple workers. In addition, the manufacturing system may require workers to have different skills at various stages during their assignment. Therefore, worker availability at each stage may vary during the scheduling horizon. Unlike traditional flexible flow shop scheduling problem, where homogeneous workers are assumed, we consider workers with different skill levels, capabilities, and capacities. We present a mixed integer linear programming model to find the optimal sequence of job assignments, guaranteeing that jobs follow their predefined operation sequence while assigning workers with various skill sets in a flexible flow shop environment. The proposed model is tested at a battery manufacturing company. By analyzing the solution, we confirm its capability to represent the problem accurately. The proposed model offers a systematic scheduling approach for a flexible flow shop environment with a heterogeneous workforce and can be implemented in other industries. © 2025 Elsevier B.V., All rights reserved.