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.     

汽车混流装配线的混合布谷鸟算法排序研究

为解决汽车混流装配线作业者工作负荷不均衡的问题,构建了最小化违背装配频率上限次数的优化模型,提出了布谷鸟算法与遗传算法相结合的混合算法。该方法将遗传算法的选择与交叉思想引入布谷鸟算法的迭代过程,以克服布谷鸟算法寻优过程中收敛速度慢和容易陷入局部最优的问题。测试函数的对比求解和合作汽车企业的优化实例表明该改进算法具有更高的求解精度和更快的收敛速度,能有效地解决大规模的汽车混流装配线排序优化问题。     

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.     

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.     

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.     

A simulated annealing algorithm based approach for balancing and sequencing of mixed-model U-lines

It is known that two interrelated problems called as line balancing and model sequencing should be solved simultaneously for an efficient implementation of a mixed-model U-shape assembly line in a JIT (Just in Time) environment. On the other hand, three versions of assembly line balancing problem can be identified: Type I, Type II, and Type E. There are only two articles ( Kara, Ozcan, & Peker, 2007a and Hamzadayi & Yildiz, 2012) related to simultaneous balancing and sequencing of mixed-model U-lines for minimizing the number of stations (Type 1 problem) by ignoring the fixed model sequence in the current literature. In this paper, a simulated annealing algorithm is proposed for solving a problem of type 1 by ignoring the fixed model sequence. Accordingly, simulated annealing based fitness evaluation approach proposed by Hamzadayi and Yildiz (2012) is enhanced by adding the tabu list, and inserted into the proposed algorithm. Implementation difficulties experienced in meta-heuristics based on solution modification for solving these types of problems are demonstrated. ‘Absolute deviation of workloads’ (ADW) is quite frequently used as performance criteria in the literature. It is found that ADW is an insufficient performance criterion for evaluating the performance of the solutions, and this is showed by means of an illustrative example. The parameters of the proposed algorithm are reviewed for calibrating the algorithm by means of Taguchi design of experiments. Performance of the proposed approach is tested through a set of test problems. The results of computational experiments indicate that the proposed approach is an effective method in solving simultaneous line balancing/model sequencing problems for mixed-model U-lines for minimizing the number of stations.     

Hybridizing ant colony optimization via genetic algorithm for mixed-model assembly line balancing problem with sequence dependent setup times between tasks

This paper presents a new hybrid algorithm, which executes ant colony optimization in combination with genetic algorithm (ACO-GA), for type I mixed-model assembly line balancing problem (MMALBP-I) with some particular features of real world problems such as parallel workstations, zoning constraints and sequence dependent setup times between tasks. The proposed ACO-GA algorithm aims at enhancing the performance of ant colony optimization by incorporating genetic algorithm as a local search strategy for MMALBP-I with setups. In the proposed hybrid algorithm ACO is conducted to provide diversification, while GA is conducted to provide intensification. The proposed algorithm is tested on 20 representatives MMALBP-I extended by adding low, medium and high variability of setup times. The results are compared with pure ACO pure GA and hGA in terms of solution quality and computational times. Computational results indicate that the proposed ACO-GA algorithm has superior performance.     

Genetic algorithms for sequencing problems in mixed model assembly lines

Mixed model assembly lines are a type of production line where a variety of product models similar in product characteristics are assembled. The effective utilisation of these lines requires that a schedule for assembling the different products be determined. In this paper, the performance of genetic algorithms for sequencing problems in mixed model assembly lines is investigated. The problem first considered is a comparison between a existing heuristic and the proposed genetic algorithm to get the constant usage of every part used by the line considering variation at multi levels (Number of levels fixed as four. level 1—product, level 2—subassembly, level 3—component, level 4—raw-materials) for various test-bed problems. The algorithms proposed by Miltenburg and Sinnamon hereafter referred to as MS 1992 [IIE Trans. 24 (1992) 121] and the proposed genetic algorithm (GA) applied to mixed model assembly line are compared. Results of evaluation indicate that the GA performs better over MS1992 on 25 of the 40 problems investigated.

The other problem solved is a multiple objective sequencing problem in mixed model assembly lines. Three practically important objectives are minimizing total utility work keeping a constant rate of part-usage, minimizing the variability in parts usage and minimizing total setup cost. In this paper, the performance of the selection mechanisms, the Pareto stratum-niche cubicle and the selection based on scalar fitness function value are compared with respect to the objective of minimising variation in part-usage, minimising total utility work and minimising the setup cost. Results of evaluation indicate that the genetic algorithm that uses the Pareto stratum-niche cubicle performs better than the genetic algorithm with the other selection mechanisms.     

A hybrid genetic algorithm for mixed model assembly line balancing problem with parallel workstations and zoning constraints

In this paper, we propose a hybrid genetic algorithm to solve mixed model assembly line balancing problem of type I (MMALBP-I). There are three objectives to be achieved: to minimize the number of workstations, maximize the workload smoothness between workstations, and maximize the workload smoothness within workstations. The proposed approach is able to address some particular features of the problem such as parallel workstations and zoning constraints. The genetic algorithm may lack the capability of exploring the solution space effectively. We aim to improve its exploring capability by sequentially hybridizing the three well known heuristics, Kilbridge & Wester Heuristic, Phase-I of Moodie & Young Method, and Ranked Positional Weight Technique, with genetic algorithm. The proposed hybrid genetic algorithm is tested on 20 representatives MMALBP-I and the results are compared with those of other algorithms.     

基于遗传算法的某航空发动机装配车间优化调度

航空发动机装配车间装配生产线的调度问题,是一类比较典型的混合Flowshop问题,同时还带有工件可重人等特点,这就区别于一般的Flowshop和Jobshop调度问题,因此,将可重入混合车间调度问题划为第三类调度问题。关于重入式混合车间生产调度的优化问题通常来说都是属于NP难问题。文中通过某航空发动机装配车间生产线的研究,以最小化最大完工时间为目标函数,借助随机矩阵的编码方式和改进的交叉方法与变异方法,提出了基于遗传算法的调度优化方法。最后实验结果表明,文中提出的改进算法能够有效地实现装配车间调度的优化。     

An effective hybrid honey bee mating optimization algorithm for balancing mixed-model two-sided assembly lines

Mixed-model two-sided assembly lines are widely used in a range of industries for their abilities of increasing the flexibility to meet a high variety of customer demands. Balancing assembly lines is a vital design issue for industries. However, the mixed-model two-sided assembly line balancing (MTALB) problem is NP-hard and difficult to solve in a reasonable computational time. So it is necessary for researchers to find some efficient approaches to address this problem. Honey bee mating optimization (HBMO) algorithm is a population-based algorithm inspired by the mating process in the real colony and has been applied to solve many combinatorial optimization problems successfully. In this paper, a hybrid HBMO algorithm is presented to solve the MTALB problem with the objective of minimizing the number of mated-stations and total number of stations for a given cycle time. Compared with the conventional HBMO algorithm, the proposed algorithm employs the simulated annealing (SA) algorithm with three different neighborhood structures as workers to improve broods, which could achieve a good balance between intensification and diversification during the search. In addition, a new encoding and decoding scheme, including the adjustment of the final mated-station, is devised to fit the MTALB problem. The proposed algorithm is tested on several sets of instances and compared with Mixed Integer Programming (MIP) and SA. The superior results of these instances validate the effectiveness of the proposed algorithm.     

求解混杂生产调度问题的嵌套混合蚁群算法

蚁群算法作为解决优化问题的有力工具,它的有效性已经得到了证明.由于其生物学背 景,基本蚁群算法被设计来求解复杂的排序类型组合优化问题,在连续空间优化问题的求解方面 研究很少.本文提出一种嵌套混合蚁群算法,用于解决具有混杂变量类型的复杂生产调度问题, 在一种新的最佳路径信息素更新算法的基础上,提高了搜索效率.计算机仿真结果表明,本文提 出的方法在求解此类问题上性能优于另一种基于进化计算的有效方法--遗传算法.     

Integrated Set Parts Supply system in a mixed-model assembly line

The mixed-model assembly line (MMAL) is a type of assembly line in which a variety of product models are assembled on the same line. The use of highly variant parts on the assembly line need to be considered carefully to enable satisfactory material flow control and allow for smooth production. To increase the quality of parts supply and parts assembly in MMAL, Toyota has introduced an innovation system known as Set Parts Supply (SPS). In this paper, we investigate the parts supply issues in SPS implementation using a case study in the automotive industry. The linkage of parts supply strategies with Manufacturing Execution System (MES) is introduced to improve the SPS implementation which are (i) synchronized parts supply, (ii) e-kanban system and (iii) Synchronized Supply Sheet. From the research findings, the integration with MES has contributed to the Just In Time in parts supply at the supermarket area and assembly line.     

Hybrid flowshop with unrelated machines, sequence-dependent setup time, availability constraints and limited buffers

This paper presents a genetic algorithm for an important production scheduling problem. Since the problem is NP-hard, we focus on suboptimal scheduling solutions for the hybrid flowshop with unrelated machines, sequence-dependent setup time, availability constraints, and limited buffers. The production environment of a television assembly line for inserting electronic components is considered. The proposed genetic algorithm is a modified and extended version of the algorithm for a problem without limited buffers. It takes into account additional limited buffer constraints and uses a new crossover operator and stopping criteria. Experimental results carried out on real production settings show an improvement in scheduling when the proposed algorithm is used.