Consideration of workforce differences in assembly line balancing and worker assignment problem

Abstract Workforce differences in terms of skill, age, gender and physical measures have a large impact on production systems performance. Moreover, the role of differences between workers can be particularly seen in assembly lines, where a vast range of tasks are performed manually, and workers are involved widely. In this work, we introduce a new assembly line balancing and worker assignment model with consideration of workers’ diversity in terms of both workers’ expertise and perceived physical effort to implement an age-inclusive workforce. Here, a new Worker Task Categorization Matrix is introduced to assure the complete involvement of the individual during the balancing process. Following, a bi-objective linear programming model is proposed and solved by using the ϵ -constraint approach. Finally, we test and validate the model through a real-case application.