An imperialist competitive algorithm for a mixed-model assembly line sequencing problem

This paper presents a novel imperialist competitive algorithm (ICA) to a just-in-time (JIT) sequencing problem where variations of production rate are to be minimized. This type of problem is NP-hard. Up to now, some heuristic and meta-heuristic approaches are proposed to minimize the production rates variation. This paper presents a novel algorithm for optimization which inspired by imperialistic competition in real world. Sequences of products where minimize the production rates variation is desired. Performance of the proposed ICA was compared against a genetic algorithm (GA) in small, medium and large problems. Experimental results show the ICA performance against GA.     

A sequencing problem for a mixed-model assembly line in a JIT production system

In an assembly line of a just-in-time (JIT) production system, workers have the power and the responsibility to stop the line when they fail to complete their operations within their work zones. This paper deals with a sequencing problem for the mixed-model assembly conveyor line in the JIT production system. In some environment, the most important criterion is the line stoppage rather than the variation of production rates. The problem is to find an optimal sequence of units that minimizes the total line stoppage time. Lower and upper bounds of the total line stoppage time are derived and the branch-and-bound method is applied to the problem. A numerical example is given.     

Scheduling a single vehicle in the just-in-time part supply for a mixed-model assembly line

This paper focuses on the scheduling of a single vehicle, which delivers parts from a storage centre to workstations in a mixed-model assembly line. In order to avoid part shortage and to cut down total inventory holding and travelling costs, the destination workstation, the part quantity and the departure time of each delivery have to be specified properly according to predetermined assembly sequences. In this paper, an optimisation model is established for the configuration that only one destination workstation is involved within each delivery. Four specific properties of the problem are deduced, then a backward-backtracking approach and a hybrid GASA (genetic algorithm and simulated annealing) approach are developed based on these properties. Both two approaches are applied to several groups of instances with real-world data, and results show that the GASA approach is efficient even in large instances. Furthermore, the existence of feasible solutions (EOFS) is analysed via instances with different problem settings, which are obtained by an orthodox experimental design (ODE). An analysis of variance (ANOVA) shows that the buffer capacity is the most significant factor influencing the EOFS. Besides this, both the assembly sequence length and distances to workstations also have noticeable impacts.     

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.     

Simultaneous solving of balancing and sequencing problems with station-dependent assembly times for mixed-model assembly lines

In spite of many studies, investigating balancing and sequencing problems in Mixed-Model Assembly Line (MMAL) individually, this paper solves them simultaneously aiming to minimize total utility work. A new Mixed-Integer Linear Programming (MILP) model is developed to provide the exact solution of the problem with station-dependent assembly times. Because of NP-hardness, a Simulated Annealing (SA) is applied and compared to the Co-evolutionary Genetic Algorithm (Co-GA) from the literature. To strengthen the search process, two main hypotheses, namely simultaneous search and feasible search, are developed contrasting Co-GA. Various parameters of SA are reviewed to calibrate the algorithm by means of Taguchi design of experiments. Numerical results statistically show the efficiency and effectiveness of the proposed SA in terms of both the quality of solution and the time of achieving the best solution. Finally, the contribution of each hypothesis in this superiority is analyzed.     

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 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 real-time sequence control system for the level production of the automobile assembly line

In the automobile industry, mixed-model assembly lines are used to produce many different vehicles without carrying large inventory. For achieving high productivity, it is required to keep a constant rate of usage of parts used by the assembly line. We have developed a new dynamic sequencing method for level production of assembly line and built up an automated sequence-control system which had been operated manually. In this paper, we present i) the nature of sequence control problems, ii) a dynamic sequence control algorithm, and iii) the experience of automating a buffer control system.     

混流装配生产线准时化物料补给调度方法

针对准时化顺序供应的混流装配生产线物料补给问题进行数学规划建模,通过决策各次物料补给作业的发车时间和料箱标号使线边物料的库存成本最小.为了解决这一复杂的混合优化问题,给出了问题的性质分析,并将该问题转化为求解最优料箱配送序列的组合优化问题.在此基础上,构建反向动态规划求解算法以获得该问题的最优解,并证明该算法具有指数级别的时间复杂度.为了求解中大规模调度问题,构建了改进蜂群算法,通过在邻域搜索部分融合基于分布估计算法的个体更新机制来强化基本蜂群算法的收敛性能.最后通过仿真实验验证了所提出算法的可行性和有效性.     

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 Lagrangean relaxation approach for the mixed-model flow line sequencing problem

In this study, a mixed-model flow line sequencing problem is considered. A mixed-model flow line is a special case of production line where products are transported on a conveyor belt, and different models of the same product are intermixed on the same line. We have focused on product-fixed, rate-synchronous lines with variable launching. Our objective function is minimizing makespan. A heuristic algorithm based on Lagrangean relaxation is developed for the problem, and tested in terms of solution quality and computational efficiency.     

A tools-system in decentralized production management systems

A “Multi-Layered Parallel Production Management” concept and its support tools-system for decentralized production management are proposed, on the basis of a “Sector optimization” concept and a “Tools-system” concept. The necessity for introducing a production system decentralization with a long range/total systematic view, for realizing a flexible and effective production management, is first discussed. Then, discussion is centered on production management quality enhancement and its support methodology. Further, a tools-system for “Multi-Layered Parallel Production Management” support is proposed and its applications are discussed.     

基于维护计划的卷烟生产线设备运维管理系统

介绍了一个基于维护计划的卷烟生产线设备运维管理系统,分别从系统功能模型、计划业务流程等角度描述了系统的设计思想。并阐述了系统涉及的设备润滑计划制定、派工、运行维护数据分析、系统开发与应用等关键技术。开发的系统具有一定的可集成性、可扩展性和可重构性,与移动通讯技术、数据采集技术相结合,集成在制造执行系统中,可以实现卷烟生产企业制丝、卷包生产线的实时设备运行与维护保养管理。     

Job shop scheduling—A systematic approach

A systematic analysis of shop performance versus different scheduling rules is presented in this paper using a computer simulation model of a conventional job shop as a basis. The simulation model is used to identify dependent parameters such as shop load and service distribution for a set of scheduling rules. These conditions should represent different existing shop conditions. Six different scheduling rules and two different performance measures were used in the analysis. A complete statistical analysis and categorization of the simulation results were performed which produced some interesting anticipated as well as unanticipated results.     

Simulation-based optimization of personnel assignment planning in sequenced commercial vehicle assembly: A software tool for iterative improvement

This paper presents a simulation-based planning software for high complexity production settings which currently undergoes first real-data industry application tests in commercial vehicle assembly. The system will also be applicable in other industries with a sufficiently high number of products and variants. The solution enables the forecasting of required personnel and temporary additional workers (“floaters”) for every cycle at the production line. It periodically collects process times, sequence and feature data for the vehicles. The cumulated workload is calculated under consideration of flexibilities. A web-based user interface enables to set and change reference data, define process simulations and to compile diagrams and charts for the analysis of the results of the different simulation runs. Various filters as to time periods, vehicle types or feature variants allow the planner a target-oriented analysis and provide feedback for improving production line tacting. Finally, some qualitative results of a first industry test in commercial vehicle assembly give feedback about the usability of existing analytical features and desirable additional features.     

A novel dynamic genetic algorithm-based method for vehicle scheduling in cross docking systems with frequent unloading operation

An important factor for efficiently managing the supply chain is to efficiently control the physical flow of the supply chain. For this purpose, many companies try to use efficient methods to increase customer satisfaction and reduce costs. Cross docking is a good method to reduce the warehouse space requirements, inventory management costs, and turnaround times for customer orders. This paper proposes a novel dynamic genetic algorithm-based method for scheduling vehicles in cross docking systems such that the total operation time is minimized. In this paper, it is assumed that a temporary storage is placed at the shipping dock and inbound vehicles are allowed to repeatedly enter and leave the dock to unload their products. In the proposed method of this paper two different kinds of chromosome for inbound and outbound trucks are proposed. In addition, some algorithms are proposed including initialization, operational time calculation, crossover and mutation for inbound and outbound trucks, independently. Moreover a dynamic approach is proposed for performing crossover and mutation operation in genetic algorithm. In order to evaluate the performance of the proposed algorithm of this paper, various examples are provided and analyzed. The computational results reveal that the proposed algorithm of this paper performs better than two well-known works of literature in providing solutions with shorter operation time.     

Heuristics for operator allocation and sequencing in just-in-time flow line manufacturing cell

Group technology tries to exploit the similarity between parts and machines and forms machine groups and part families. Just-in-time production tries to manufacture the parts whenever required there by reducing the inventory and eliminating waste.

In order to apply JIT in a GT cell, the cell is divided into modules and parts move from one module to another in small transfer batches. This paper addresses the problem of operator allocation for the modules and sequencing the variety of parts with the objective of minimizing the makespan.

Six different methodologies have been presented and the results compared in terms of makespan and computational time.     

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.     

A batch scheduling scheme for the workcenter that supplies parts to a mixed-model assembly line

The factory considered in this study consists of a mixed-model assembly line and a workcenter. The mixed-model assembly line (main line) simultaneously produces different product models whose assembly parts are provided in batches by the workcenter. The main purpose of this study is to develop a batch scheduling scheme for the workcenter. The objective function of the scheduling is to provide parts for the main line without delays. The problems that make the scheduling challengeable are as follows: (1) different product models being simultaneously produced on the main line require different parts and (2) space for part inventory in the workcenter is limited. This study presents two batch scheduling approaches used to build a real system for the workcenter.