Profit-oriented balancing of two-sided disassembly lines with resource-dependent task times

Purpose As a result of environmentally conscious production requirements in the world, the concept of disassembly has been a focus of interest by researchers and practitioners over the last two decades. Disassembly is an important process in circular economy to recover and reuse of parts and materials. End-of-life and large-sized products such as minibuses and trucks may be disassembled on two-sided lines. The ability of using both right and left sides of two-sided lines may increase line efficiency and reduce space requirements across the line. This paper aims to address a two-sided disassembly line balancing problem (TSDLBP), which deals with assigning disassembly tasks, various equipments and assistants to the workstations to maximize total net recovery profit of the line. Design/methodology/approach A detailed explanation of the TSDLBP is first presented in the paper. A new 0–1 integer linear programming model is then proposed for the TSDLBP, aiming at maximizing total net recovery profit from disassembly of products. A set of test problems is generated, and an experimental analysis is conducted to make a comparison between traditional one-sided disassembly lines (TOSDL) and two-sided disassembly lines by means of performance improvement rate. Findings Optimal results are obtained in 132 (81.48%) out of 162 the TOSDL balancing problems, while 92 (56.79%) out of 162 the TSDLBP using the proposed model. Total net recovery profits are compared on 88 problems for which optimal solutions are obtained in both the TOSDL and the TSDLBP. Results showed that implementing two-sided disassembly lines provides 29.18% increment in total net recovery profit compared to the TOSDL. Furthermore, the effects of different parameter levels on the net recovery profit are analyzed using two-way analysis of variance. According to the results, implementing two-sided disassembly line configuration increases total net recovery profit of the line significantly compared to traditional disassembly line configuration. Originality/value The use of disassembly lines has become essential because of increasing consumption that results in a huge number of end-of-life products in the world. Two-sided disassembly lines may be preferred for dismantling large-sized products due to their high disassembly capacity and fewer space requirements. This paper proposes a new mathematical model for disassembly line balancing problem. The proposed model differs from the existing models by means of efficiently assigning limited disassembly resources as well as assigning disassembly tasks to the workstations to maximize total net recovery profit of the production system. The model allows decision-makers to consider several resource limitations when balancing their disassembly lines. The paper also provides a comprehensive experimental study to compare traditional and two-sided disassembly lines by means of profitability of disassembly processes.