Modeling and solving the mixed-model sequencing problem to improve productivity

Bautista, Joaquı́n; Alfaro, Rocío; Batalla, Cristina

doi:10.1016/j.ijpe.2014.11.018

Cited by 23 publications

(20 citation statements)

References 26 publications

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“…First, m2 shows workstations that, under the conditions of the reference line configuration ψ 0 , need more cycle time to fulfill all the production plans of E. Manufacturing process management technologies can offer the following solutions to solve this issue: a) improve the processing time of the industrial tasks (methods-time measurement (MTM)), b) request alternative pieces having less processing time during their assembly (product design department), and c) set a working pace over the normal activity of the line (Bautista et al 2015) within the legal and trade union agreements (process engineering).…”

Section: Using the Metrics And Computational Methods To Measure Managmentioning

confidence: 99%

A multiobjective model and evolutionary algorithms for robust time and space assembly line balancing under uncertain demand

Chica

Bautista

Cordón

et al. 2016

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Changes in demand when manufacturing different products require an optimization model that includes robustness in its definition and methods to deal with it. In this work we propose the r-TSALBP, a multiobjective model for assembly line balancing to search for the most robust line configurations when demand changes. The robust model definition considers a set of demand scenarios and presents temporal and spatial overloads of the stations in the assembly line of the products to be assembled. We present two multiobjective evolutionary algorithms to deal with one of the r-TSALBP variants. The first algorithm uses an additional objective to evaluate the robustness of the solutions. The second algorithm employs a novel adaptive method to evolve separate populations of robust and non-robust solutions during the search. Results show the improvements of using robustness information during the search and the outstanding behavior of the adaptive evolutionary algorithm for solving the problem. Finally, we analyze the managerial impacts of considering the r-TSALBP model for the different organization departments by exploiting the values of the robustness metrics.

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Section: Using the Metrics And Computational Methods To Measure Managmentioning

confidence: 99%

A multiobjective model and evolutionary algorithms for robust time and space assembly line balancing under uncertain demand

Chica

Bautista

Cordón

et al. 2016

Omega

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“…For this reason, we also incorporate two possible measures to counteract the negative effect of saturation conditions on productivity. First, we incorporate into the model the activity concept according the work by Bautista, Alfaro and Batalla (2015a). In this way the activation of workers at certain times of their workday will reduce productivity losses due to the limits of saturation.…”

Section: Mmsp-w: Mixed-model Sequencing Problem With Workload Minimizmentioning

confidence: 99%

“…* = 1.2. Bautista et al, (2015a) established a direct correlation between the activity factor and the stress level over time, taking into consideration firstly, the idea from Robert Yerkes and John Dodson, who said that when stress increases up to a certain optimum point of stress, the operators' performance improves; and, secondly, the idea that worker's performance varies throughout the working day, and therefore, the relationship between the operators' performance and their level of "activation", which is reflected by their level of stress, follows a concave function (Muse, Harris and Field, 2003). Thanks to this correlation the authors defined, first, a stepped function for the work pace factor throughout time (Bautista, C onsideration of human resources in the Mixed-Model Sequencing Problem with Work O verload M inimization: Legal provisions and productivity improvement J. Bautista, R. Alfaro-Pozo, C. Batalla-García…”

Section: Processing Times and Work Pace Factormentioning

confidence: 99%

“…Increase the activation level of the processors (based on activity factor) like Bautista, Alfaro and Batalla made in their work (Bautista et al, 2015a). In this way, the work assigned to each processor will be carried out in less time, and thus, the ratio between the total available time and the real work time will be reduced.…”

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“…Alfaro, Batalla and Cano, 2014) and, afterwards, three additional functions, the triangular, the trapezoidal and the parabolic one (Bautista et al, 2015a).…”

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Consideration of human resources in the Mixed-model Sequencing Problem with Work Overload Minimization: Legal provisions and productivity improvement

Bautista

Alfaro-Pozo

Batalla-García

2015

Expert Systems with Applications

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Abstract:Beginning with a variation of the sequencing problem in a mixed-products line (MMSP-W: Mixed-Model Sequencing Problem with Workload Minimization), we propose two new models that incorporate a set of working conditions in regard with human resources of workstations on the line. These conditions come from collective agreements and therefore must be respected by both company and labor unions. The first model takes into account the saturation limit of the workstations, and the second model also includes the activation of the operators throughout the working day. Two computational experiments were carried out using a case study of the Nissan motor plant in Barcelona with two main objectives: (1) to study the repercussions of the saturation limit on the decrease in productivity on the line and (2) to evaluate the recovery of productivity on the line via both activation of operators, while maintaining the same quality in working conditions achieved by limiting the saturation, and auxiliary processors. By results we state that saturation limitation leads an important increase of work overload, which means average economic losses of 28,731.8 Euros/day. However, the productivity reduction may be counteracted by the work pace factor increase, at certain moments of workday, and/or by the incorporation of auxiliary processors into the line.Keywords: Sequencing; Mixed-product line; Work overload; Saturation; Activity factor; Manufacturing operations. PreliminariesCurrently, many production systems exist in which the manufacture or assembly of an entire product (or a subcomponent of the product) is carried out on the production line. At the same time, the increasing market requirements demand that companies offer a wide range of products with different options. This situation is commonly found in the automotive industry in which different products are manufactured and although these products belong to the same family, they have variable characteristics that require different component consumption and resource use, such as different processing times of operations. Obviously, not all vehicles share the same type of motor, and not all are equipped with the same components.Assembly lines in the automotive industry are a clear example of this type of mixedproduct lines, which are known as Mixed-model Assembly Line (MMAL). In this type of C onsideration of human resources in the Mixed-Model Sequencing Problem with Work O verload M inimization: Legal provisions and productivity improvement J. Bautista, R. Alfaro-Pozo, C. Batalla-García 2 lines, different components (seats, steering wheels, pedals, etc.) are incorporated into the vehicle body depending on the type of vehicle that is assembled at each moment. Therefore, these lines must be flexible and able to adapt to each type of product assembled in them without incurring excessive costs.In this way, to increase flexibility and reduce costs in terms of both workforce and storage, the MMALs face two basic problems: (1) the balancing of the line, known in the literature as th...

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Productivity Improvement, Considering Legal Conditions and Just in Time Principles in the Mixed-Model Sequencing Problem

Valhondo

Alfaro-Pozo

Batalla-García

2016

Lecture Notes in Management and Industrial Engineering

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A new mathematical model to solve the Mixed-Model Sequencing Problem with Work overload minimization is formulated. The model incorporates productive, social and legal aspects in order to move the theory problem closer to the actual industrial environments. Specifically, there are considered the variation of work pace of workers throughout the workday to increase the completed work; the conditions of occupancy level of workers imposed by the collective agreements; and the idea of keeping constant the production mix through the sequence leading both to a balance between the required workloads at stations and regular consumption of components. Indeed, by means of a case study linked to Nissan, a gain of over 98% is achieved in terms of regular cumulative production and required work, while performing the 100% of required work and following legal restrictions of operators' saturation.

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Modeling and solving the mixed-model sequencing problem to improve productivity

Cited by 23 publications

References 26 publications

A multiobjective model and evolutionary algorithms for robust time and space assembly line balancing under uncertain demand

A multiobjective model and evolutionary algorithms for robust time and space assembly line balancing under uncertain demand

Consideration of human resources in the Mixed-model Sequencing Problem with Work Overload Minimization: Legal provisions and productivity improvement

Productivity Improvement, Considering Legal Conditions and Just in Time Principles in the Mixed-Model Sequencing Problem

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