A Hybrid Machine Learning–Genetic Algorithm for Optimizing Surface-Mount Technology Planning

We tackle the problem of improving the Surface- Mount Technology (SMT) process planning in an automotive manufacturing setting. Current simulations show low accu- racy across production lines as the existing approach relies on predefined setups rather than adapting to product-specific configurations. We propose a hybrid framework that couples machine learning with a genetic algorithm to generate product- specific plans. Our solution involves three tasks: (i) assigning boards to lines, (ii) allocating components to Pick-and-Place (PnP) machines, and (iii) balancing workloads across machines. Our hybrid pipeline embeds supervised learning in a genetic optimizer. A multi-class classifier selects feasible PnP head con- figurations per Bill of Materials (BOM) part number (precision = 0.73). A genetic algorithm assigns components to compatible feeder tables/machines, while a regression model estimates table cycle times (R² = 0.88). The fitness jointly optimizes Components Placed per Hour (CPH) and Line Balancing (LB) under process constraints. Different mutation methods are explored, revealing that mutation based on balancing the workload by leveling the number of placements on the tables with minimum and maximum cycle time results in an LB of 0.83, with a CPH of 0.37 and an average delta cycle time of -3.27% across 105-part numbers