Balancing and scheduling of flexible mixed model assembly lines

Mixed model assembly line literature involves two problems: balancing and model sequencing. The general tendency in current studies is to deal with these problems in different time frames. However, in today’s competitive market, the mixed model assembly line balancing problem has been turned into an operational problem. In this paper, we propose mixed integer programming (MIP) and constraint programming (CP) models which consider both balancing and model sequencing within the same formulation along with the optimal schedule of tasks at a station. Furthermore, we also compare the proposed exact models with decomposition schemes developed for solving different instances of varying sizes. This is the first paper in the literature which takes into account the network type precedence diagrams and limited buffer capacities between stations. Besides, it is the first study that CP method is applied to balancing and scheduling of mixed model assembly lines. Our empirical study shows that the CP approach outperforms the MIP approach as well as the decomposition schemes.     

2-ANTBAL: An ant colony optimisation algorithm for balancing two-sided assembly lines

Two-sided assembly lines are a special type of assembly lines in which workers perform assembly tasks in both sides of the line. This type of lines is of crucial importance, especially in the assembly of large-sized products, like automobiles, buses or trucks, in which some tasks must be performed at a specific side of the product. This paper presents an approach to address the two-sided mixed-model assembly line balancing problem. First, a mathematical programming model is presented to formally describe the problem. Then, an ant colony optimisation algorithm is proposed to solve the problem. In the proposed procedure two ants ‘work’ simultaneously, one at each side of the line, to build a balancing solution which verifies the precedence, zoning, capacity, side and synchronism constraints of the assembly process. The main goal is to minimise the number of workstations of the line, but additional goals are also envisaged. The proposed procedure is illustrated with a numerical example and results of a computational experience that exhibit its superior performance are presented.     

Mixed model assembly line design in a make-to-order environment

Mixed model assembly lines can be found today in many industrial environments. With the growing trend for greater product variability and shorter life cycles, they are replacing the traditional mass production assembly lines. In many cases, these lines follow a ‘make-to-order’ production policy, which reduces the customer lead-time, and is expressed in a random arrival sequence of different model types to the line. Additional common characteristics of such mixed model lines in a make-to-order environment are: small numbers of work stations, a lack of mechanical conveyance, and highly skilled workers. The design problem of mixed model assembly lines in a make-to-order environment is addressed in this paper. A mathematical formulation is presented which considers the differences between our model and traditional models. A heuristic that minimizes the number of stations for a predetermined cycle time is developed consisting of three stages: the balancing of a combined precedence diagram, balancing each model type separately subject to the constraints resulting from the first stage, and a neighborhood search based improvement procedure.     

An advanced multiobjective genetic algorithm design for the time and space assembly line balancing problem

Time and space assembly line balancing considers realistic multiobjective versions of the classical assembly line balancing industrial problems involving the joint optimization of conflicting criteria such as the cycle time, the number of stations, and/or the area of these stations. In addition to their multi-criteria nature, the different problems included in this field inherit the precedence constraints and the cycle time limitations from assembly line balancing problems, which altogether make them very hard to solve. Therefore, time and space assembly line balancing problems have been mainly tackled using multiobjective constructive metaheuristics. Global search algorithms in general - and multiobjective genetic algorithms in particular - have shown to be ineffective to solve them up to now because the existing approaches lack of a proper design taking into account the specific characteristics of this family of problems. The aim of this contribution is to demonstrate the latter assumption by proposing an advanced multiobjective genetic algorithm design for the 1/3 variant of the time and space assembly line balancing problem which involves the joint minimization of the number and the area of the stations given a fixed cycle time limit. This novel design takes the well known NSGA-II algorithm as a base and considers the use of a new coding scheme and sophisticated problem specific operators to properly deal with the said problematic questions. A detailed experimental study considering 10 different problem instances (including a real-world instance from the Nissan plant in Barcelona, Spain) will show the good yield of the new proposal in comparison with the state-of-the-art methods.     

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.     

基于遗传算法的焊接生产线工位平衡规划方法

在现代化大规模大批量的流水装配制造业中,数量众多的作用分配和多工位的合理安排使工位平衡问题显得更为突出。针对第一类工位平衡问题,即在给定的生产节拍下最小化工位数,首先分析了该问题并建立了数学模型,进而提出了一种基于改进遗传算法求解工位平衡问题的方法。该算法以焊接任务的操作顺序优先关系为约束前提,在初始种群的生产以及交叉和变异过程中保证了染色体解的可行性,同时在遗传算法的选择过程中考虑了具有相同工位数的最优作业方案的工时标准差,从而提高了算法的搜索效率和解的可靠性。最后通过实例求解验证了该算法的有效性。     

A multi-objective TLBO algorithm for balancing two-sided assembly line with multiple constraints

Two-sided assembly line is often designed to produce large-sized high-volume products such as cars, trucks and engineering machinery. However, in real-life production process, besides the elementary constraints in the one-sided assembly line, additional constraints, such as zoning constraints, positional constraints and synchronous constraints, may occur in the two-sided assembly line. In this paper, mathematical formulation of balancing multi-objective two-sided assembly line with multiple constraints is established, and some practical objectives, including maximization of the line efficiency, minimization of the smoothness index and minimization of the total relevant costs per product unit (Tcost), have been considered. A novel multi-objective optimization algorithm based on improved teaching–learning-based optimization (ITLBO) algorithm is proposed to obtain the Pareto-optimal set. In the ITLBO algorithm, teacher and learner phases are modified for the discrete problem, and late acceptance hill-climbing is integrated into a novel self-learning phase. A novel merging method is proposed to construct a new population according to the ordering relation between the original and evolutionary population. The proposed algorithm is tested on the benchmark instances and a practical case. Experimental results, compared with the ones computed by other algorithm and in current literature, validate the effectiveness of the proposed algorithm.     

The type E simple assembly line balancing problem: A mixed integer linear programming formulation

Although the simple assembly line balancing problem (SALBP) is the topic of many studies, typically they either consider minimizing the number of stations for a given cycle time (called type one), or minimizing the cycle time for a given number of stations (called type two). Rarely, type E of the problem has been considered. In the type E, cycle time and number of stations are both decision variables, and the objective is to maximize the line efficiency. This paper presents a mixed integer linear programming formulation for the type E simple assembly line balancing problem. Moreover, to further strengthen the presented formulation, two enhancement techniques in the form of valid inequalities and auxiliary variables are proposed. As the secondary objectives of the problem, minimization of the number of stations, the cycle time, and the smoothness index are studied as well. In the case of workload smoothing, three different linearization methods are employed and compared for minimizing the smoothness index. The results of computational study on the benchmark data set demonstrate the efficacy of the improved formulation     

蚁群算法求解装配线平衡第一类问题

装配线平衡问题是生产管理中重要且较难解决的问题,其中第一类问题是装配线平衡问题的关键问题。本文通过对装配线平衡问题的分析与建模,提出了利用蚁群算法这种人工智能优化算法求解一般装配线平衡第一类问题的步骤和算法。采用启发式的方法构造分配方案的生成策略,并对信息素的更新采用局部更新与全局更新相结合的规则,从而使得该算法具有较好的目的性,大大提高了获得最优解的效率。通过该蚁群算法能得到装配线平衡第一类问题质量较优的解,且有速度快、鲁棒性、通用性等优势。     

A branch and bound method for the line balancing problem in U-shaped assembly lines with equipment requirements

In this study we consider a U-shaped assembly line balancing problem where each task uses a specified set of equipments and each type of equipment has a specified cost. Our problem is to assign the tasks together with their equipments to the workstations so as to minimize the total equipment cost. We formulate the problem as a mixed integer linear programming model that is capable of solving small sized instances. We propose a branch and bound algorithm that uses efficient precedence relations and lower bounds. We find that the algorithm is able to solve moderate sized problem instances in reasonable times.     

Modeling and solving constrained two-sided assembly line balancing problem via bee algorithms

Designing and operating two-sided assembly lines are crucial for manufacturing companies which assemble large-sized products such as trucks, buses and industrial refrigerators. This type of assembly line structure has several advantages over one-sided assembly lines such as shortened line length and reduced throughput time. The research area has recently focused on balancing two-sided assembly lines owing to these advantages. However, due to the complex structure of this problem, some practical constraints have been disregarded or have not been fully incorporated. In order to overcome these deficiencies, a fully constrained two-sided assembly line balancing problem is addressed in this research paper. Initially, a mathematical programming model is presented in order to describe the problem formally. Due to the problem complexity, two different swarm intelligence based search algorithms are implemented to solve large-sized instances. Bees algorithm and artificial bee colony algorithm have been applied to the fully constrained two-sided assembly line balancing problem so as to minimize the number of workstations and to obtain a balanced line. An extensive computational study has also been performed and the comparative results have been evaluated.     

Two-sided assembly line balancing using teaching–learning based optimization algorithm

Assembly line balancing plays a crucial role in modern manufacturing companies in terms of the growth in productivity and reduction in costs. The problem of assigning tasks to consecutive stations in such a way that one or more objectives are optimized subject to the required tasks, processing times and some specific constraints is called the assembly line balancing problem (ALBP). Depending on production tactics and distinguishing working conditions in practice, assembly line systems show a large diversity. Although, a growing number of researchers addressed ALBP over the past fifty years, real-world assembly systems which require practical extensions to be considered simultaneously have not been adequately handled. This study deals with an industrial assembly system belonging to the class of two-sided line with additional assignment restrictions which are often encountered in practice. Teaching–learning based optimization (TLBO), which is a recently developed nature-inspired search method, is employed to solve the line balancing problem. Computational results are compared with the current situation in terms of the line efficiency, and the solution structure with workload assigned to the stations is presented.     

A Lagrangian relaxation technique for the general assembly line balancing problem

This paper addresses the problem of balancing assembly or fabrication lines. In order to achieve a given production rate or to optimize the use of workstations, one has to tackle the problem of balancing the production lines. It is well known that this problem belongs to the class of NP-hard problems. In this paper the polyhedron of the feasible solutions of the assembly line balancing problem is first studied. Then a Lagrangian relaxation algorithm that incorporates the set of cycle constraints in the objective function is proposed. These constraints are the complicating restrictions in the model. The relaxed problem has the interesting property that its linear programming relaxation always has integer optimal solutions. The subgradient algorithm is then used to maximize the Lagrangian dual. A heuristic is also used to find primal feasible solutions for the original line balancing integer program. These two bounds are then used to reduce the size of the branch-and-bound tree.     

Bacterial Foraging Optimization Algorithm for assembly line balancing

Assembly line balancing is the problem of assigning tasks to workstations by optimizing a performance measure while satisfying precedence relations between tasks and cycle time restrictions. Many exact, heuristic and metaheuristic approaches have been proposed for solving simple straight and U-shaped assembly line balancing problems. In this study, a relatively new optimization algorithm, Bacterial Foraging Optimization Algorithm (BFOA), based heuristic approach is proposed for solving simple straight and U-shaped assembly line balancing problems. The performance of the proposed algorithm is evaluated using a well-known data set taken from the literature in which the number of tasks varies between 7 and 111, and results are also compared with both an ant-colony-optimization-based heuristic approach and a genetic-algorithm-based heuristic approach. The proposed algorithm provided optimal solutions for 123 out of 128 (96.1 %) test problems in seconds and is proven to be promising.     

Multi-criteria assembly sequencing

This paper describes the elements of a multi-criteria optimization formulation of the assembly sequencing problem. The criteria considered are: total assembly time and number of reorientations. These two criteria are combined using multi-attribute utility theory to derive a single objective function. The combined objective function has been formulated subject to the precedence constraints of the assembly process. The model has been solved using simulated annealing. The elements of the developed algorithms and their performances are demonstrated in this paper.     

Including different kinds of preferences in a multi-objective ant algorithm for time and space assembly line balancing on different Nissan scenarios

Most of the decision support systems for balancing industrial assembly lines are designed to report a huge number of possible line configurations, according to several criteria. In this contribution, we tackle a more realistic variant of the classical assembly line problem formulation, time and space assembly line balancing. Our goal is to study the influence of incorporating user preferences based on Nissan automotive domain knowledge to guide the multi-objective search process with two different aims. First, to reduce the number of equally preferred assembly line configurations (i.e., solutions in the decision space) according to Nissan plants requirements. Second, to only provide the plant managers with configurations of their contextual interest in the objective space (i.e., solutions within their preferred Pareto front region) based on real-world economical variables. We face the said problem with a multi-objective ant colony optimisation algorithm. Using the real data of the Nissan Pathfinder engine, a solid empirical study is carried out to obtain the most useful solutions for the decision makers in six different Nissan scenarios around the world.     

A genetic algorithm based approach to the mixed-model assembly line balancing problem of type II

Mixed-model assembly lines allow for the simultaneous assembly of a set of similar models of a product, which may be launched in the assembly line in any order and mix. As current markets are characterized by a growing trend for higher product variability, mixed-model assembly lines are preferred over the traditional single-model assembly lines.

This paper presents a mathematical programming model and an iterative genetic algorithm-based procedure for the mixed-model assembly line balancing problem (MALBP) with parallel workstations, in which the goal is to maximise the production rate of the line for a pre-determined number of operators.

The addressed problem accounts for some relevant issues that reflect the operating conditions of real-world assembly lines, like zoning constraints and workload balancing and also allows the decision maker to control the generation of parallel workstations.     

The definition of assembly line balancing difficulty and evaluation of balance solution quality

Assembly line balancing is a classic ill-structured problem where total enumeration is infeasible and optimal solutions uncertain for industrial problems. A quantitative approach to classifying problem difficulty and solution quality is therefore important. Two existing measures of difficulty, order strength and west ratio are compared to a new compound expression of difficulty, project index. Project index is based on individual assessment of precedence (precedence index) and task time (task time index). The current working definition of project index is given. Early criteria for judging assembly lines use balance delay and smoothness index, both are flawed as criteria. Line and balance efficiency are developed as more appropriate. Project index, line and balance efficiency will be illustrated for a published test-case examined by the “ALine” balancing package. The potential for a “learning” approach, selecting models to suit problems using the measures of difficulty, will form part of the conclusions within this paper.     

Design of a real-time AND/OR assembly scheduler on an optimization neural network

The problem of finding an AND/OR precedence-constraint assembly schedule using optimization neural computation is presented. The precedence relationships of assembly operation result from the geometric constraints of subtasks. Because of the existence of geometric constraints among assembly subtasks, the assembly operation involves AND/OR precedence relationships; that is, the order of assembly crucially determines whether the desired task can be achieved. A feasible assembly schedule is a schedule that satisfies these AND/OR precedence constraints.It has been shown that all the feasible assembly schedules can be generated by transforming geometric constraints of subtasks to the pattern-matching operation. Using the question-answer pattern and pattern-matching operation, the assembly scheduling problem can be transformed into an AND/OR precedence-constrained traveling salesman problem (TSP). Two precedence-constrained TSPs, cost-constrained TSP (CCTSP) and state-constrained TSP (SCTSP), are discussed. The CCTSP artificially sets the cost of the prohibited moves to a very large value which ensures that the constraints are satisfied, while the SCTSP restricts the movement of next assembly subtasks. The advantage of the SCTSP over CCTSP in the generation of the assembly schedule will be illustrated.A novel method proposed here is to obtain the best AND/OR precedence-constraint assembly schedule using neural network computation. The geometric constraints of an assembled object are transformed into the elements of the connection matrix which specifies the connection strength among neurons. A modified Hopfield network is used to tackle the AND/OR precedence-constraints assembly scheduling problem. Multirobot assembly sequences generation is also discussed. The designed algorithm can accommodate various constraints and applications. Detailed algorithms, examples and experiments are presented.     

Enhanced mixed integer programming model for a transfer line design problem

Modular machining lines with multi-spindle workstations are considered. A multi-spindle head executes a set of operations. The problem of optimal design or reconfiguration of such lines is considered here. The set of all available spindle heads, operations executed by each spindle head, spindle head times and costs are assumed to be known. There are operations which can be executed by one of several candidate spindle heads, i.e., in different configuration with other operations. The problem consists in the choice of spindle heads from the given set and their assignment to workstations. The goal is to minimize the line cost while satisfying the precedence, inclusion and exclusion constraints. This problem is an extension of well known assembly line balancing and equipment selection problem. In our previous work, we proposed a MIP model which was significantly limited as to the size of the problems treated. In this paper, quite a few original approaches are suggested to improve the previous MIP model. The numerical tests reported show that the calculation time is drastically decreased, thereby expanding the model to larger and more realistic industrial problems.