A MIP approach for balancing transfer line with complex industrial constraints

This paper deals with a novel line balancing problem for flexible transfer lines composed of identical CNC machines. The studied lines are paced and serial, i.e. a part to be machined passes through a sequence of workstations. At least one CNC machine is installed at each workstation. The objective is to assign a given set of operations required for the machining of the part to a sequence of workstations while minimizing the total number of machines used. This problem is subject to precedence, exclusion and inclusion constraints. In addition, accessibility has to be considered. Moreover, the workstation workload depends on the sequence in which the operations are assigned because of setup times related to the change and displacement of tools, rotation of the part, etc. It is a novel line balancing problem, and we highlight its particularities by reviewing the close problems existing in the literature. Then, a mathematical model as a mixed-integer program is suggested. A procedure for computing ranges for variables is given. Experimental computations with ILOG Cplex are reported.     

Exact and heuristic algorithms for balancing transfer lines when a set of available spindle heads is given

A balancing problem for paced tandem transfer lines with several spindle heads at each station is considered. A spindle head executes a block of operations. The set of all available spindle heads as well as the operations executed by each spindle head, the spindle head times and costs are known. There are operations with several spindle head candidates. The problem at the line design stage 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. An exact algorithm based on a mixed integer programming approach is developed. Two types of new heuristic algorithms are also suggested. One of them step‐by‐step assigns randomly spindle heads to a current workstation. The second uses depth‐first search techniques. Experimental results are reported.     

A heuristic approach for transfer lines balancing

The paper deals with optimal balancing transfer lines where the operations in each workstation are grouped into blocks. All operations of the same block are executed simultaneously by one spindle head. Spindle heads of the same workstation are activated sequentially. The workstation time is the sum of the processing times of its blocks. The problem is to find the best assignment of operations to blocks and assignment of blocks to workstations that leads to the minimal transfer line cost (a weighted sum of blocks and workstation numbers). The solution must provide a desired productivity rate (cycle time). It must also satisfy precedence and compatibility constraints. Two heuristic algorithms based on the COMSOAL technique are proposed. Results from computer testing are reported.     

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.     

Multi-rule Multi-objective Simulated Annealing Algorithm for Straight and U Type Assembly Line Balancing Problems

The task of balancing of assembly lines is of considerable industrial importance. It consists of assigning operations to workstations in a production line in such a way that (1) no assembly precedence constraint is violated, (2) no workstations in the line takes longer than a predefined cycle time to perform all tasks assigned to it, and (3) as few workstations as possible are needed to perform all the tasks in the set. This paper presents a new multiple objective simulated annealing (SA) algorithm for simple (line) and U type assembly line balancing problems with the aim of maximizing “smoothness index” and maximizing the “line performance” (or minimizing the number of workstations). The proposed algorithm makes use of task assignment rules in constructing feasible solutions. The proposed algorithm is tested and compared with literature test problems. The proposed algorithm found the optimal solutions for each problem in short computational times. A detailed performance analysis of the selected task assignment rules is also given in the paper.     

Two-machine flowshop scheduling with flexible operations and controllable processing times

We consider a two-machine flowshop scheduling problem with identical jobs. Each of these jobs has three operations, where the first operation must be performed on the first machine, the second operation must be performed on the second machine, and the third operation (named as flexible operation) can be performed on either machine but cannot be preempted. Highly flexible CNC machines are capable of performing different operations. Furthermore, the processing times on these machines can be changed easily in albeit of higher manufacturing cost by adjusting the machining parameters like the speed and/or feed rate of the machine. The overall problem is to determine the assignment of the flexible operations to the machines and processing times for each operation to minimize the total manufacturing cost and makespan simultaneously. For such a bicriteria problem, there is no unique optimum but a set of nondominated solutions. Using ?-constraint$?\mathrm{-}\mathrm{constraint}$ approach, the problem could be transformed to be minimizing total manufacturing cost for a given upper limit on the makespan. The resulting single criterion problem can be reformulated as a mixed integer nonlinear problem with a set of linear constraints. We use this formulation to optimally solve small instances of the problem while a heuristic procedure is constructed to solve larger instances in a reasonable time.     

A hybrid algorithm for allocating tasks,operators, and workstations in multi-manned assembly lines

In a car, there are approximately 30,000 parts produced by many different industries. This is due to the complexity and enormity of the automotive industry chain. The vehicle assembly process comprises welding, painting, prefabrication, and final entire-vehicle assembly. The assembly line has the largest labor force, which should be arranged and balanced to increase production efficiency and reduce labor force requirements. Unlike traditional studies on assembly line balancing problems (ALBPs), this study considers the characteristics of the automotive industry, such as multi-manned workstations, minimization in terms of the numbers of operators and workstations for streamlined production, budget constraints, the optimization of both task and operator allocation among workstations, and the determination of the start/end processing time of each task at different workstations. To address these NP-hard problems, a hybrid heuristic approach that combines the procedure of building feasible balancing solutions and the simulated annealing algorithm is proposed to map out an optimal line balancing plan for multi-manned workstations and to reduce the required workspace for shop operations. Based on the design and analysis of experiments, the effects of the maximum number of allowed operators per workstation and those of the cycle time on ALBP solutions are explored. The optimal combination of algorithm parameters is also determined. The results of this study can serve as a practical reference in planning the allocation of tasks, workstations, and operators in the industry.     

Dealing with feature interactions for prismatic parts in STEP-NC

Determining the precedence of machining features is a critical issue in feature-based process planning. It becomes more complex when geometric interaction occurs between machining features. STEP-NC, the extension of STEP (ISO 10303) standard developed for CNC controllers, is a feature-based data model. It represents all the geometric and topological product data minus feature interactions. In this paper, machining precedence of interactive and non-interactive STEP-NC features is discussed. Local and global precedence of machining features are defined on the basis of geometric constraints, such as geometric interaction of features and feature approach face and technological constraint such as access direction of the cutting tool. A software tool has been developed to visualize the STEP-NC part model and to generate the graphs of feature interaction and feature precedence. The output can be then used to augment the STEP-NC data in order to generate the optimal sequence of operations.     

Algorithms and implementation of a set partitioning approach for modular machining line design

A transfer line design problem is considered. Transfer lines are sequences of workstations equipped with processing modules called blocks each of which performs specific operations. These lines are used for mass production of one type of product and thus execute repetitively a given set of operations. The machine parts move along the stations in the same direction. An identical cost is associated with each station and differing costs are associated with the blocks. The problem is to determine the number of stations, select a set of blocks and assign selected blocks to the stations so that operations of the selected blocks constitute the original set of operations and the total cost is minimized. A distinct feature of the problem is that operations at the same station are performed in parallel. Plus, there are inclusion, exclusion and precedence relations that restrict the assignment of the blocks and operations to the same station as well as the processing order of the operations on the transfer line. We implement a novel set partitioning formulation of this design problem with pre-processing procedures and heuristics. The presented approach has the best performance among the existing methods in terms of solution time and quality.     

Fault-Tolerant Parallel Scheduling of Tasks on a Heterogeneous High-Performance Workstation Cluster

We propose a new approach, called cluster-based search (CBS), for scheduling large task graphs in parallel on a heterogeneous cluster of workstations connected by a high-speed network (e.g., using an ATM switch at OC-3 speed). The CBS algorithm uses a parallel random neighborhood search which works by refining multiple different initial schedules simultaneously using different workstations. The workstations communicate periodically to exchange their best solutions found thus far in order to direct the search to more promising regions in the search space. Heterogeneity of machines is exploited by the biased partitioning of the search space. The parallel random neighborhood search is fault-tolerant in that the workload of a failed workstation is automatically redistributed to other workstations so that the search can continue. We have implemented the CBS algorithm as a core function of our on-going development of SSI middleware for a Sun workstation cluster.     

Reduction approaches for a generalized line balancing problem

An NP-hard optimization problem dealing with the assignment of operations to the workstations and spindle heads of a machining transfer line is studied. Precedence, inclusion and exclusion constraints among the operations, capacity and cycle time constraints exist. The objective is to minimize the cost of the line being designed. This problem has been referred to as the Transfer Line Balancing Problem (TLBP) and is a generalized case of well-known simple assembly line balancing problem. In literature, few exact methods have been proposed to solve it. Since the problem is NP-hard, those that do are too time-consuming for solving real life industrial cases. This paper presents effective pre-processing methods which can reduce the size of the initial problem in order to shorten the solution time required. These methods are evaluated on three datasets of new generated problem instances and known benchmarks. The results obtained show that for certain cases the solution time can be significantly reduced when these pre-processing methods are applied.     

Firing sequences backward algorithm for simple assembly line balancing problem of type 1

The objective of simple assembly line balancing problem type-1 (SALBP-1) is to minimize the number of workstations on an assembly line for a given cycle time. Since SALBP-1 is NP-hard, many iterative backtracking heuristics based on branch and bound procedure, tabu search, and genetic algorithms were developed to solve SALBP-1. In this study, a new heuristic algorithm based on Petri net approach is presented to solve the problem. The presented algorithm makes an order of firing sequence of transitions from Petri net model of precedence diagram. Task is assigned to a workstation using this order and backward procedure. The algorithm is coded in MATLAB, and its efficiency is tested on Talbot’s and Hoffmann’s benchmark datasets according to some performance measures and classifications. Computational study validates its effectiveness on the benchmark problems. Also comparison results show that the algorithm is efficiency to solve SALBP-1.     

A Kano model,AHP and M-TOPSIS method-based technique for disassembly line balancing under fuzzy environment

Recovery, recycling or remanufacturing of post-consumed products are viable alternatives for reducing the environmental problems resulting from the huge amounts of waste currently arriving at landfills. Disassembly operations are inevitable for product recovery therefore the disassembly line is an appropriate choice to carry out the same. A disassembly line balancing problem is how to streamline the disassembly activities, so that the total disassembly time required at each workstation is approximately the same. The assignment of jobs to workstations in a disassembly environment has been the matter of concern to researchers because the product, which has to be disassembled, have different types of materials. The main aim of a disassembly process is to reuse components and reduce undesirable impact on the environment. This paper applies a Kano model, fuzzy-AHP, and M-TOPSIS-based technique, shown to successfully find the optimal order of component removal using AND/OR precedence relation. The tasks are assigned to the disassembly workstations according to their priority rank and precedence relations. The proposed technique has been illustrated with an example and the results show improvements in the performance in comparison with other techniques.     

Bicriteria robotic operation allocation in a flexible manufacturing cell

Consider a manufacturing cell of two identical CNC machines and a material handling robot. Identical parts requesting the completion of a number of operations are to be produced in a cyclic scheduling environment through a flow shop type setting. The existing studies in the literature overlook the flexibility of the CNC machines by assuming that both the allocation of the operations to the machines as well as their respective processing times are fixed. Consequently, the provided results may be either suboptimal or valid under unnecessarily limiting assumptions for a flexible manufacturing cell. The allocations of the operations to the two machines and the processing time of an operation on a machine can be changed by altering the machining conditions of that machine such as the speed and the feed rate in a CNC turning machine. Such flexibilities constitute the point of origin of the current study. The allocation of the operations to the machines and the machining conditions of the machines affect the processing times which, in turn, affect the cycle time. On the other hand, the machining conditions also affect the manufacturing cost. This study is the first to consider a bicriteria model which determines the allocation of the operations to the machines, the processing times of the operations on the machines, and the robot move sequence that jointly minimize the cycle time and the total manufacturing cost. We provide algorithms for the two 1-unit cycles and test their efficiency in terms of the solution quality and the computation time by a wide range of experiments on varying design parameters.     

A hybrid ant colony algorithm for U-line balancing and rebalancing in just-in-time production environment

U-line balancing is an important problem for designing a new U-line. It is about combining a finite set of tasks to form workstations optimally with the restriction of given precedence relationships in a new U-line. As the demand varies, the U-line should be rebalanced to eliminate waste and improve the production efficiency as part of just-in-time principles. If all machines can be moved freely, the rebalancing problem equals to the balancing problem. In practice, some machines are stationary or need certain moving cost. In this paper, U-line rebalancing problem is formalized with respect to minimization the moving cost of machines and labor cost. The walking time of operators is considered to avoid generating awkward walking path. A new hybrid algorithm of ant colony optimization and filtered beam search is presented to solve the problem. The hybrid algorithm adopts the framework of ant colony optimization. In the process of constructing path, each ant explores several nodes for one step and chooses the best one by global and local evaluation at a given probability. Computational results show that the proposed algorithm performs quite effectively for solving U-line balancing problems in the literature by comparing to the existing solutions. Finally, the proposed algorithm for solving U-line rebalancing problem is demonstrated with an example and also yields optimal solutions.     

A GA-based approach for optimizing single-part flow-line configurations of RMS

Generating economical single-part flow-line (SPFL) configurations as candidates for a given demand period is an important optimization problem for reconfigurable manufacturing systems (RMS). The optimization problem addresses the questions of selecting number of workstations, number and type of paralleling identical machines as well as operation setups (OSs) for each workstation. The inputs include a precedence graph for a part, relationships between OSs and operations, machine options for each OS. The objective is to minimize the capital costs of the SPFL configurations. A 0–1 nonlinear programming (NLP) model is developed to handle the key issue of sharing machine utilization over consecutive OSs which is ignored in existing 0–1 integer linear programming (ILP) model. Then a GA-based approach is proposed to identify a set of economical solutions. To overcome the complexity of search space, a novel procedure is presented to guide GA to search within a refined solution space comprising the optimal configurations associated with feasible OS sequences. A case study shows that the best solution derived from the 0–1 NLP model through GA is better than the optimum of existing 0–1 ILP model. The results illustrate the effectiveness of our model and the efficiency of the GA-based approach.     

Assembly line balancing in garment industry

Garment manufacturing is a traditional industry with global competition. The most critical manufacturing process is sewing, as it generally involves a great number of operations. The aim of assembly line balance planning in sewing lines is to assign tasks to the workstations, so that the machines of the workstation can perform the assigned tasks with a balanced loading. Assembly line balancing problem (ALBP) is known as an NP-hard problem. Thus, the heuristic methodology could be a better way to plan the sewing lines within a reasonable time.This paper develops a grouping genetic algorithm (GGA) for ALBP of sewing lines with different labor skill levels in garment industry. GGA can allocate workload among machines as evenly as possible for different labor skill levels, so the mean absolute deviations (MAD) can be minimized. Real data from garment factories and experimental design are used to evaluate GGA’s performance. Production managers can use the research results to quickly design sewing lines for important targets such as short cycle time and high labor utilization.     

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.     

On the search of workstations arrangement in pull production systems

This research presents a model to determine the workstation arrangement and kanban number for pull production systems. Several practical production line characters are considered, and evolutionary algorithms are utilized to obtain the optimal/near-optimal result. The proposed system is a flow-shop, pull production line with N unreliable workstations and N ? 1 inter-stage buffers. Workstations may be allocated to any stage in the production line and have a different processing rate at each stage. Workstations will breakdown/recover at fixed rates, and the operating-breakdown-recovery process is formulated as a Markov process in this model. The size of the inter-stage buffers varies according to the arrangements of workstations. A model is established on the objective of minimizing the total production cost per item of the finished product. The costs considered in the system contain the allocation of workstations, operations, inventory, and production shortage costs. An evolutionary algorithm, genetic algorithm, is used to obtain the allocation of workstations in the production line.