A Stochastic Sequence-Dependent Disassembly Line Balancing Problem with an Adaptive Large Neighbourhood Search Algorithm

The remanufacturing of end-of-life products is an effective approach to alleviating resource shortages, environmental pollution, and global warming. As the initial step in the remanufacturing process, the quality and efficiency of disassembly have a decisive impact on the entire workflow. However, the complexity of product structures poses numerous challenges to practical disassembly operations. These challenges include not only conventional precedence constraints among disassembly tasks but also sequential dependencies, where interference between tasks due to their execution order can prolong operation times and complicate the formulation of disassembly plans. Additionally, the inherent uncertainties in the disassembly process further affect the practical applicability of disassembly plans. Therefore, developing reliable disassembly plans must fully consider both sequential dependencies and uncertainties. To this end, this paper employs a chance-constrained programming model to characterise uncertain information and constructs a multi-objective sequence-dependent disassembly line balancing (MO-SDDLB) problem model under uncertain environments. The model aims to minimise the hazard index, workstation time variance, and energy consumption, achieving a multi-dimensional optimisation of the disassembly process. To efficiently solve this problem, this paper designs an innovative multi-objective adaptive large neighbourhood search (MO-ALNS) algorithm. The algorithm integrates three destruction and repair operators, combined with simulated annealing, roulette wheel selection, and local search strategies, significantly enhancing solution efficiency and quality. Practical disassembly experiments on a lithium-ion battery validate the effectiveness of the proposed model and algorithm. Moreover, the proposed MO-ALNS demonstrated a superior performance compared to other state-of-the-art methods. On average, against the best competitor results, MO-ALNS improved the number of Pareto solutions (NPS) by approximately 21%, reduced the inverted generational distance (IGD) by about 21%, and increased the hypervolume (HV) by nearly 8%. Furthermore, MO-ALNS exhibited a superior stability, providing a practical and feasible solution for disassembly optimisation.