A hybrid multi-objective shuffled frog-leaping algorithm for a mixed-model assembly line sequencing problem

In this paper, a mixed-model assembly line (MMAL) sequencing problem is studied. This type of production system is used to manufacture multiple products along a single assembly line while maintaining the least possible inventories. With the growth in customers’ demand diversification, mixed-model assembly lines have gained increasing importance in the field of management. Among the available criteria used to judge a sequence in MMAL, the following three are taken into account: the minimization of total utility work, total production rate variation, and total setup cost. Due to the complexity of the problem, it is very difficult to obtain optimum solution for this kind of problems by means of traditional approaches. Therefore, a hybrid multi-objective algorithm based on shuffled frog-leaping algorithm (SFLA) and bacteria optimization (BO) are deployed. The performance of the proposed hybrid algorithm is then compared with three well-known genetic algorithms, i.e. PS-NC GA, NSGA-II, and SPEA-II. The computational results show that the proposed hybrid algorithm outperforms the existing genetic algorithms, significantly in large-sized problems.     

A multi-objective scatter search for a mixed-model assembly line sequencing problem

A mixed-model assembly line (MMAL) is a type of production line where a variety of product models similar to product characteristics are assembled. There is a set of criteria on which to judge sequences of product models in terms of the effective utilization of this line. In this paper, we consider three objectives, simultaneously: minimizing total utility work, total production rate variation, and total setup cost. A multi-objective sequencing problem and its mathematical formulation are described. Since this type of problem is NP-hard, a new multi-objective scatter search (MOSS) is designed for searching locally Pareto-optimal frontier for the problem. To validate the performance of the proposed algorithm, in terms of solution quality and diversity level, various test problems are made and the reliability of the proposed algorithm, based on some comparison metrics, is compared with three prominent multi-objective genetic algorithms, i.e. PS-NC GA, NSGA-II, and SPEA-II. The computational results show that the proposed MOSS outperforms the existing genetic algorithms, especially for the large-sized problems.     

A new particle swarm algorithm for a multi-objective mixed-model assembly line sequencing problem

The sequencing of products for mixed-model assembly line in Just-in-Time manufacturing systems is sometimes based on multiple criteria. In this paper, three major goals are to be simultaneously minimized: total utility work, total production rate variation, and total setup cost. A multi-objective sequencing problem and its mathematical formulation are described. Due to the NP-hardness of the problem, a new multi-objective particle swarm (MOPS) is designed to search locally Pareto-optimal frontier for the problem. To validate the performance of the proposed algorithm, various test problems are solved and the reliability of the proposed algorithm, based on some comparison metrics, is compared with three distinguished multi-objective genetic algorithms (MOGAs), i.e. PS-NC GA, NSGA-II, and SPEA-II. Comparison shows that MOPS provides superior results to MOGAs.     

A multi-objective genetic algorithm for mixed-model assembly line rebalancing

When demand structure or production technology changes, a mixed-model assembly line (MAL) may have to be reconfigured to improve its efficiency in the new production environment. In this paper, we address the rebalancing problem for a MAL with seasonal demands. The rebalancing problem concerns how to reassign assembly tasks and operators to candidate stations under the constraint of a given cycle time. The objectives are to minimize the number of stations, workload variation at each station for different models, and rebalancing cost. A multi-objective genetic algorithm (moGA) is proposed to solve this problem. The genetic algorithm (GA) uses a partial representation technique, where only a part of the decision information about a candidate solution is expressed in the chromosome and the rest is computed optimally. A non-dominated ranking method is used to evaluate the fitness of each chromosome. A local search procedure is developed to enhance the search ability of moGA. The performance of moGA is tested on 23 reprehensive problems and the obtained results are compared with those by other authors.     

A multi-objective mixed-model assembly line sequencing problem in order to minimize total costs in a Make-To-Order environment,considering order priority

Nowadays, mixed-model assembly line is used increasingly as a result of customers’ demand diversification. An important problem in this field is determining the sequence of products for entering the line. Before determining the best sequence of products, a new procedure is introduced to choose important orders for entering the shop floor. Thus the orders are sorted using an analytical hierarchy process (AHP) approach based on three criteria: critical ratio of each order (CR_o), Significance degree of customer and innovation in a product, while the last one is presented for the first time. In this research, six objective functions are presented: minimizing total utility work cost, total setup cost and total production rate variation cost are the objectives which were presented previously, another objective is minimizing total idle cost, meanwhile two other new objectives regarding minimizing total operator error cost and total tardiness cost are presented for the first time. The total tardiness cost tries to choose a sequence of products that minimizes the tardiness cost for customers with high priority. First, to check the feasibility of the model, GAMS software is used. In this case, GAMS software could not search all of the solution space, so it is tried in two stages and because this problem is NP-hard, particle swarm optimization (PSO) and simulated annealing (SA) algorithms are used. For small sized problems, to compare exact method with proposed algorithms, the problem must be solved using meta-heuristic algorithms in two stages as GAMS software, whereas for large sized problems, the problem can be solved in two ways (one stage and two stages) by using proposed algorithms; the computational results and pairwise comparisons (based on sign test) show GAMS is a proper software to solve small sized problems, whereas for a large sized problem the objective function is better when solved in one stage than two stages; therefore it is proposed to solve the problem in one stage for large sized problems. Also PSO algorithm is better than SA algorithm based on objective function and pairwise comparisons.     

Modeling and solving mixed-model assembly line balancing problem with setups. Part I: A mixed integer linear programming model

This paper is the first one of the two papers entitled “modeling and solving mixed-model assembly line balancing problem with setups”, which has the aim of developing the mathematical programming formulation of the problem and solving it with a hybrid meta-heuristic approach. In this current part, a mixed-integer linear mathematical programming (MILP) model for mixed-model assembly line balancing problem with setups is developed. The proposed MILP model considers some particular features of the real world problems such as parallel workstations, zoning constraints, and sequence dependent setup times between tasks, which is an actual framework in assembly line balancing problems. The main endeavor of Part-I is to formulate the sequence dependent setup times between tasks in type-I mixed-model assembly line balancing problem. The proposed model considers the setups between the tasks of the same model and the setups because of the model switches in any workstation. The capability of our MILP is tested through a set of computational experiments. Part-II tackles the problem with a multiple colony hybrid bees algorithm. A set of computational experiments is also carried out for the proposed approach in Part-II.     

Mixed-model assembly line balancing in the make-to-order and stochastic environment using multi-objective evolutionary algorithms

The present study introduces a multi-objective genetic algorithm (MOGA) to solve a mixed-model assembly line problem (MMALBP), considering cycle time (CT) and the number of stations simultaneously. A mixed-model assembly line is one capable of producing different types of products to respond to different market demands, while minimizing on capital costs of designing multiple assembly lines. In this research, according to the stochastic environment of production systems, a mixed-model assembly line has been put forth in a make-to-order (MTO) environment. Furthermore, a MOGA approach is presented to solve the corresponding balancing problem and the decision maker is provided with the subsequent answers to pick one based on the specific situation. Finally, a comparison is carried out between six multi-objective evolutionary algorithms (MOEA) so as to determine the best method to solve this specific problem.     

Solving a bi-criteria permutation flow-shop problem using shuffled frog-leaping algorithm

Flow shop problems as a typical manufacturing challenge have gained wide attention in academic fields. In this paper, we consider a bi-criteria permutation flow shop scheduling problem, where the weighted mean completion time and the weighted mean tardiness are to be minimized simultaneously. Due to the complexity of the problem, it is very difficult to obtain optimum solution for this kind of problems by means of traditional approaches. Therefore, a new multi-objective shuffled frog-leaping algorithm (MOSFLA) is introduced for the first time to search locally Pareto-optimal frontier for the given problem. To prove the efficiency of the proposed algorithm, various test problems are solved and the reliability of the proposed algorithm, based on some comparison metrics, is compared with three distinguished multi-objective genetic algorithms, i.e. PS-NC GA, NSGA-II, and SPEA-II. The computational results show that the proposed MOSFLA performs better than the above genetic algorithms, especially for the large-sized problems.     

Developing a multi-objective,multi-item inventory model and three algorithms for its solution

We develop a multi-objective model in a multi-product inventory system.The proposed model is a joint replenishment problem(JRP) that has two objective functions.The first one is minimization of total ordering and inventory holding costs,which is the same objective function as the classic JRP.To increase the applicability of the proposed model,we suppose that transportation cost is independent of time,is not a part of holding cost,and is calculated based on the maximum of stored inventory,as is the case in many real inventory problems.Thus,the second objective function is minimization of total transportation cost.To solve this problem three efficient algorithms are proposed.First,the RAND algorithm,called the best heuristic algorithm for solving the JRP,is modified to be applicable for the proposed problem.A multi-objective genetic algorithm(MOGA) is developed as the second algorithm to solve the problem.Finally,the model is solved by a new algorithm that is a combination of the RAND algorithm and MOGA.The performances of these algorithms are then compared with those of the previous approaches and with each other,and the findings imply their ability in finding Pareto optimal solutions to 3200 randomly produced problems.     

A hybrid genetic algorithm for multi-objective product plan selection problem with ASP and ALB

Facing current environment full of a variety of small quantity customized requests, enterprises must provide diversified products for speedy and effective responses to customers’ requests. Among multiple plans of product, both assembly sequence planning (ASP) and assembly line balance (ALB) must be taken into consideration for the selection of optimal product plan because assembly sequence and assembly line balance have significant impact on production efficiency. Considering different setup times among different assembly tasks, this issue is an NP-hard problem which cannot be easily solved by general method. In this study the multi-objective optimization mathematical model for the selection of product plan integrating ASP and ALB has been established. Introduced cases will be solved by the established model connecting to database statistics. The results show that the proposed Guided-modified weighted Pareto-based multi-objective genetic algorithm (G-WPMOGA) can effectively solve this difficult problem. The results of comparison among three different kinds of hybrid algorithms show that in terms of the issues of ASP and ALB for multiple plans, G-WPMOGA shows better problem-solving capability for four-objective optimization.