A Simulation Study for Implementing Color Rescheduling Storage in an                 Automotive Factory

Moon, Dug Hee; Kim, Ha Seok; Song, Cheng

doi:10.1177/0037549704047604

Cited by 19 publications

(4 citation statements)

References 5 publications

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“…Spieckermann et al [ 6 ] present a formulation of the color-batching process as a sequential ordering problem and propose a branch-and-bound (B&B) algorithm to find the optimal output sequence with the minimum number of color changes. Moon et al [ 7 ] conduct a simulation study for designing and implementing a color rescheduling storage (CRS) in an automotive factory and suggest some simple fill and release policies for operating the selectivity bank. Hartmann and Runkler [ 8 ] present two ant colony optimization (ACO) algorithms to enhance simple rule-based color-batching methods.…”

Section: Literature Reviewmentioning

confidence: 99%

Environment-Aware Production Scheduling for Paint Shops in Automobile Manufacturing: A Multi-Objective Optimization Approach

Zhang

2017

IJERPH

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The traditional way of scheduling production processes often focuses on profit-driven goals (such as cycle time or material cost) while tending to overlook the negative impacts of manufacturing activities on the environment in the form of carbon emissions and other undesirable by-products. To bridge the gap, this paper investigates an environment-aware production scheduling problem that arises from a typical paint shop in the automobile manufacturing industry. In the studied problem, an objective function is defined to minimize the emission of chemical pollutants caused by the cleaning of painting devices which must be performed each time before a color change occurs. Meanwhile, minimization of due date violations in the downstream assembly shop is also considered because the two shops are interrelated and connected by a limited-capacity buffer. First, we have developed a mixed-integer programming formulation to describe this bi-objective optimization problem. Then, to solve problems of practical size, we have proposed a novel multi-objective particle swarm optimization (MOPSO) algorithm characterized by problem-specific improvement strategies. A branch-and-bound algorithm is designed for accurately assessing the most promising solutions. Finally, extensive computational experiments have shown that the proposed MOPSO is able to match the solution quality of an exact solver on small instances and outperform two state-of-the-art multi-objective optimizers in literature on large instances with up to 200 cars.

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Section: Literature Reviewmentioning

confidence: 99%

Environment-Aware Production Scheduling for Paint Shops in Automobile Manufacturing: A Multi-Objective Optimization Approach

Zhang

2017

IJERPH

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“…Han et al (2003) developed a finite-horizon model for resequencing a set of jobs on a moving assembly line, with the objective of minimising the changeover cost, and determined the optimal solution through simulation. Moon et al (2005) conducted a simulation study related to the design and implementation of colour rescheduling storage (CRS) with a loop buffer in an automotive factory. Moon (2010) investigated the problem of minimising setup costs in resequencing jobs at conveyor junctions with off-line buffers under the FIFO constraint.…”

Section: Literature Reviewmentioning

confidence: 99%

Designing insert buffers for mixed-model assembly lines

Matsuura

Asada

2017

AJMSA

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To meet a diverse range of manufacturing specifications and keep pace with rapid changes in consumer requirements, mixed-model assembly lines must become more efficient and flexible than they are at present. This study examines the characteristics of an insert buffer that uses the curved portion of a mixed-model assembly line to provide guidelines for designing the buffer, and then analyses the number of sequences generated with the buffer. Also analysed is the effect of the insert buffer on the working time and line length. Based on these results, a procedure for designing an insert buffer is proposed.

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“…Some researchers have studied the colour-batching process using selectivity banks. Moon, Kim, and Song (2005) performed a simulation study for designing and implementing a selectivity bank in the paint shop of an automotive factory. Simple placing and releasing algorithms were applied in operating the selectivity bank.…”

Section: Introductionmentioning

confidence: 99%

A colour-batching problem using selectivity banks in automobile paint shops

Sun

Fan

Shao

et al. 2014

International Journal of Production Research

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This paper studies the colour-batching problem frequently raised in automobile paint shops, where selectivity banks are used as storage and retrieval systems to execute practices of resequencing car bodies before painting operations are performed. The purpose of resequencing is to obtain colour-oriented batches of cars in order to reduce setup costs incurred in paint shops. In this paper, two heuristic procedures, arraying and shuffling heuristics, are developed aimed at quickly and effectively achieving good colour-batching results. The arraying heuristic can be applied in the car placing stage, while the shuffling heuristic can be utilised in the car releasing stage. Computational experiments are carried out to evaluate the performance of the proposed heuristics. It is shown that the shuffling heuristic can generate comparable car retrieval sequences with an exact branch & bound approach, and the proposed arraying and shuffling heuristics can be jointly applied to achieve good colour batching in a very short time duration of less than 0.4 s in comparison with two existing batching methods. These research findings can provide good insights into the practice of colour batching in automobile manufacturing.

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A Simulation Study for Implementing Color Rescheduling Storage in an Automotive Factory

Cited by 19 publications

References 5 publications

Environment-Aware Production Scheduling for Paint Shops in Automobile Manufacturing: A Multi-Objective Optimization Approach

Environment-Aware Production Scheduling for Paint Shops in Automobile Manufacturing: A Multi-Objective Optimization Approach

Designing insert buffers for mixed-model assembly lines

A colour-batching problem using selectivity banks in automobile paint shops

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