Optimizing Disassembly Line Balancing with Consideration of Disassembly Depth and Uncertainties

Disassembly of end-of-life (EoL) products is a critical enabler of product reuse and the extension of usage cycles within the circular economy. However, the economic efficiency of the disassembly processes remains a major barrier, particularly in high-wage countries. Due to heterogeneous EoL product conditions and the need for process adaptability, disassembly is often performed manually by skilled workers. To ensure cost-effectiveness, it is essential to minimize non-value-adding activities and maximize worker utilization. A promising method to improve efficiency is the use of divergent disassembly depths, where certain disassembly steps are intentionally omitted. While this approach reduces processing time and improves labor efficiency, it introduces complexity into linked disassembly systems, particularly with regard to line balancing. Omitted disassembly steps can lead to workstation imbalances and utilization losses. This paper introduces a Disassembly Line Balancing (DLB) approach tailored to processes with divergent disassembly depths. A simplified simulation model is implemented, enabling effective balancing and improved productivity. Furthermore, the study validates key uncertainties and evaluates their impact on overall performance.