Modelling and solving mixed-model two-sided assembly line balancing problem with sequence-dependent setup time

Yang, Wucheng; Cheng, Wenming

doi:10.1080/00207543.2019.1683255

Cited by 30 publications

(4 citation statements)

References 48 publications

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“…The significance of scheduling models that account for setup times has been explored in multiple studies [57][58][59][60]. Separating setup times from processing times enables simultaneous operations, thereby enhancing resource utilization [56]. This approach is in line with the principles of modern production management systems, including JIT, Optimized Production Technology (OPT), and Group Technology (GT), supporting the need for explicit consideration of setup times in scheduling models [61].…”

Section: Kouvelis and Karabatimentioning

confidence: 92%

“…However, it is often assumed that the setup times required for changing the assembly line from one product model to another are minimal and do not impact overall operations [55]. This assumption is challenged by recent discussions highlighting the critical impact of setup times on scheduling quality, especially when assembly stations operate near total capacity [56]. The significance of scheduling models that account for setup times has been explored in multiple studies [57][58][59][60].…”

Section: Kouvelis and Karabatimentioning

confidence: 99%

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Optimizing Mixed-Model Synchronous Assembly Lines with Bipartite Sequence-Dependent Setup Times in Advanced Manufacturing

Varyani,

Salehi,

Heydari Gharahcheshmeh

2024

Energies

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In advanced manufacturing, optimizing mixed-model synchronous assembly lines (MMALs) is crucial for enhancing productivity and adhering to sustainability principles, particularly in terms of energy consumption and energy-efficient sequencing. This paper introduces a novel approach by categorizing sequence-dependent setup times into bipartite categories: workpiece-independent and workpiece-dependent. This strategic division streamlines assembly processes, reduces idle times, and decreases energy consumption through more efficient machine usage. A new mathematical model is proposed to minimize the intervals at which workpieces are launched on an MMAL, aiming to reduce operational downtime that typically leads to excessive energy use. Given the Non-deterministic Polynomial-time hard (NP-hard) nature of this problem, a genetic algorithm (GA) is developed to efficiently find solutions, with performance compared against the traditional branch and bound technique (B&B). This method enhances the responsiveness of MMALs to variable production demands and contributes to energy conservation by optimizing the sequence of operations to align with energy-saving objectives. Computational experiments conducted on small and large-sized problems demonstrate that the proposed GA outperforms the conventional B&B method regarding solution quality, diversity level, and computational time, leading to energy reductions and enhanced cost-effectiveness in manufacturing settings.

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Section: Kouvelis and Karabatimentioning

confidence: 92%

Section: Kouvelis and Karabatimentioning

confidence: 99%

Optimizing Mixed-Model Synchronous Assembly Lines with Bipartite Sequence-Dependent Setup Times in Advanced Manufacturing

Varyani,

Salehi,

Heydari Gharahcheshmeh

2024

Energies

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“…Özcan [27] paralel montaj hatlarındaki hazırlık süreleri ile ilgilenmiş, çözüm için ikili doğrusal matematiksel model önermiş ve tavlama benzetimi algoritması geliştirmiştir. Yang ve Cheng [28] hazırlık süreli karışık modelli çift taraflı MHDP için karışık tam sayılı bir matematiksel model sunmuş, çözüm için değişken komşuluk algoritması (variable neighbourhood search) önermiştir.…”

Section: Literatür Taraması (Literature Review)unclassified

Kaynak ve sıra bağımlı hazırlık süreli montaj hattı dengeleme problemi (KHMHDP)

Kılınçcı

2022

Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi

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Klasik basit montaj hattı dengeleme problemi (BMHDP), son yıllarda birçok gerçek-dünya uygulamaları ile farklılaştırılmaktadır. Bunlardan birisi sıra bağımlı kurulum süreli montaj hattı dengeleme problemidir (SBKSMHDP). Bu çalışmada SBKSMHDP, her iş istasyonunda iki kaynak bulunması ile farklılaştırılmaktadır. İş istasyonlarında, aynı kaynak kullanılarak yapılan işlemler arasındaki kurulumlara odaklanılmıştır. Çalışılan problem kaynak ve sıra bağımlı kurulum süreli montaj hattı dengeleme problemi (KSBKSMHDP) olarak adlandırılmıştır. Problem, eş zamanlı olarak, işlemin iş istasyonuna atanması, işlemin kaynağa atanması ve aynı kaynak kullanılarak yapılan işlemlerin sıralanmasıdır. Problem çözümü için bir Genetik Algoritma geliştirilmiştir. KSBKSMHDP için bir veri seti yaratılmış ve geliştirilen algoritma veri seti kullanılarak test edilmiştir. Sonuçlar, geliştirilen algoritmanın SBKSMHDP’ye göre hat üzerindeki toplam iş istasyonu sayılarını azalttığını göstermektedir

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“…In the case of sequence-dependent setup times occurrence [2], binary linear mathematical programming (BLP) model and a simulated annealing (SA) algorithm are proposed to model and solve balancing and scheduling tasks. In reference [24], a mixed-integer programming (MIP) mathematical model is used to formulate mixed-model two-sided assembly lines problem. An effective variable neighborhood search (VNS) algorithm is proposed to solve the balancing problem, especially for the large-sized problems.…”

mentioning

confidence: 99%

Utilization of Industry 4.0 Related Equipment in Assembly Line Balancing Procedure

et al. 2020

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In recent decades, production in high-volume/low-variety batches is replaced with low-volume/high-variety production type. This type of production demands excessive flows of both material and information. Recent advances in information and communication technologies (ICT), together with the concept of cyber-psychical system (CPS) enable the concept of Industry 4.0 (I4.0). In this paper, the performance of I4.0 related equipment implementation is presented in iterative assembly line balancing (ALB) process of a gearbox assembly line. Largest candidate rule method through spreadsheet simulation was used for tasks reallocations, with the objective to minimize the cycle time when the number of stations is fixed. Utilization of human analysts using snap back method for manual data gathering process still shown advantage over I4.0 equipment utilization in manual ALB. The assembly process is performed in the learning factory environment, and it is considered as very close to real industry process. The major conclusion is that I4.0 is excellent in process data monitoring and product tracking, but activities to be performed to effectively exploit I4.0 is demanding for task reallocations during the balancing procedure. Nevertheless, future enhancements of I4.0 system are listed to bridge this gap and to increase I4.0 system usefulness in the manual assembly line balancing process.

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Modelling and solving mixed-model two-sided assembly line balancing problem with sequence-dependent setup time

Cited by 30 publications

References 48 publications

Optimizing Mixed-Model Synchronous Assembly Lines with Bipartite Sequence-Dependent Setup Times in Advanced Manufacturing

Optimizing Mixed-Model Synchronous Assembly Lines with Bipartite Sequence-Dependent Setup Times in Advanced Manufacturing

Kaynak ve sıra bağımlı hazırlık süreli montaj hattı dengeleme problemi (KHMHDP)

Utilization of Industry 4.0 Related Equipment in Assembly Line Balancing Procedure

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