A hybrid constraint programming and cross-entropy approach for balancing U-Shaped disassembly line with flexible workstations and spatial constraints

Abstract

Disassembly lines are an effective means for the large-scale, industrialized recycling of end-of-life products. Among these, U-shaped disassembly lines are particularly noted for their combination of flexibility and production efficiency. This study addresses the U-shaped disassembly line balancing problem, considering the coexistence of separate stations and spatial limitations within workstations. A mixed-integer nonlinear programming model and a constraint programming model are developed to accurately capture this complex problem. Additionally, a novel hybrid constraint programming with a goal-driven cross-entropy optimization algorithm (CP–GDCE) is introduced. This algorithm combines a multi-objective cross-entropy grouping framework, a constraint programming-based heuristic initialization, a multi-point crossover recombination mechanism, and large neighborhood search techniques, significantly enhancing solution efficiency and accuracy. Extensive benchmarking and experimental validation indicate that the CP–GDCE not only excels in addressing the specific problem of this study but also demonstrates superiority in classic disassembly line balancing issues. In 21 test cases, the CP–GDCE achieved superior hypervolume and inverted generational distance values compared to 11 benchmark algorithms. A practical application using a printer disassembly example shows that the proposed U-shaped configuration is highly flexible and efficient, compatible with both traditional U-shaped and straight disassembly lines. This configuration significantly reduces the total length of the disassembly line, improving space utilization and highlighting its practical potential and advantages.