A Cuckoo Search Algorithm to Solve Transfer Line Balancing Problems With Different Cutting Conditions

An automated transfer line balancing problem is investigated in this paper. The line produces a complex part at a high volume, such as cylinder heads, and incorporates identical machines that can be operated under different cutting conditions. The selection of cutting conditions significantly influences productivity and the cost of the transfer line. The production of cylinder heads requires machining different operations within a given takt time and satisfying precedence, inclusion, and exclusion relationships. The operations are located on different faces of the cylinder head and are processed by different cutting tools. The line balancing problem is studied to identify the optimal cutting conditions, number of machines and tools, and machining sequence of operations. The objective is to design a balanced transfer line at a minimum machining and tooling cost, and also with minimum nonproductive time. The problem is represented by a goal-programming model and solved for small transfer line configurations through linearization. An improved cuckoo search algorithm via Levy flight is developed to solve large-scale instances. Results of the cuckoo algorithm are promising since it reached optimal and close-to-optimal solutions to small problems and surpassed the results of a random local search approach for instances of medium and large problems.