Branch and bound algorithm for a transfer line design problem: Stations with sequentially activated multi-spindle heads

In this paper, a new transfer line balancing problem is considered. The main difference from the simple assembly line balancing problem is that the operations are grouped into blocks (batches). All the operations of the same block are carried out simultaneously by one piece of equipment (multi-spindle head). Nevertheless, the blocks assigned to the same workstation are executed in series. The line cost consists of the sum of block and workstation costs. At the considered line design stage, the set of all available blocks is given. The aim is to find a subset from the given set of available blocks and to find a partition of this subset to workstations such that each operation is executed once and the line cost is minimal while all the precedence, cycle time, and compatibility (operation inclusion and block exclusion) constraints are respected. A new lower bound based on solving a special set partitioning problem is presented and a branch and bound algorithm is developed. The experimental results prove the quality of the lower bound and applicability of the suggested branch and bound algorithm for medium sized industrial cases.     

A special case of transfer lines balancing by graph approach

A balancing problem for paced production lines with workstations in series and blocks of parallel operations at the workstations is considered. Operations of each workstation are partitioned into blocks. All operations of the same block are performed simultaneously by one spindle head. All blocks of the same workstation are also executed simultaneously. The relations of the necessity of executing some operations at the same workstation, the possibility of combining the blocks at the same workstation as well as precedence constraints are given. The operation time of the workstation is the maximal value among operation times of its blocks. The line cycle time is the maximal workstation time. The problem is to choose blocks from a given set and allocate them to workstations in such a way that (i) all the operations are assigned, (ii) the above constraints are satisfied, (iii) a given cycle time is not exceeded, and (iv) the line cost is minimal. A method for solving the problem is based on its transformation to a constrained shortest path problem.     

Optimisation of multi-position machines and transfer lines

A new optimisation problem for design of multi-position machines and automatic transfer lines is considered. To reduce the number of pieces of equipment, machining operations are grouped into blocks. The operations of the same block are performed simultaneously by one piece of equipment (multi-spindle head). At the studied design stage, constraints related to the design of blocks and workstations, as well as precedence constraints for operations are known. The problem consists in an optimal grouping of the operations into blocks minimizing the total number of blocks and workstations while reaching a given cycle time (productivity). A constrained shortest path algorithm is developed and tested.     

Tabu search algorithms for an industrial multi-product and multi-objective assembly line balancing problem,with reduction of the task dispersion

This paper presents a real-world industrial application of the multi-product and multi-objective assembly line balancing problem, for a company involved in the production of four models of a white goods product. The problem solved is a GALBP-2, with 10 workstations and multiple objectives (to maximize the production rate in order to deal with an increase of the demand forecasted, to reach an equal cycle time of all the models and an equal workload of the different workstations, and finally, to minimize the dispersion of worker tasks on each one of the different models—the common tasks of the different models at the same workstation). The paper presents an integrated approach based on four heuristics cited in the literature and: (1) an improvement procedure based on tabu search, with the objective of minimizing the cycle time; and, subsequently, (2) a second tabu search in order to increase the uniformity of the tasks performed at each workstation (the common tasks at the same workstation).     

A heuristic multi-start decomposition approach for optimal design of serial machining lines

We study an optimal design problem for serial machining lines. Such lines consist of a sequence of stations. At every station, the operations to manufacture a product are grouped into blocks. The operations within each block are performed simultaneously by the same spindle head and the blocks of the same station are executed sequentially. The inclusion and exclusion constraints for combining operations into blocks and stations as well as the precedence constraints on the set of operations are given. The problem is to group the operations into blocks and stations minimizing the total line cost. A feasible solution must respect the given cycle time and all given constraints. In this paper, a heuristic multi-start decomposition approach is proposed. It utilizes a decomposition of the initial problem into several sub-problems on the basis of a heuristic solution. Then each obtained sub-problem is solved by an exact algorithm. This procedure is repeated many times, each time it starts with a new heuristic solution. Computational tests show that the proposed approach outperforms simple heuristic algorithms for large-scale problems.     

Operations planning for a multi-stage kanban system

A multi-stage production line which operates under a just-in-time production philosophy with linear demand is considered here. The first workstation processes the raw materials after receiving them from suppliers, a kanban mechanism between the workstations transports the work-in-process to the succeeding workstation, and after processing them, delivers the finished products to a buyer or a warehouse. The problem is to find optimally the number of raw material orders, kanbans circulated between workstations, finished goods shipments to the buyers, and the batch size for each shipment (lot). A cost function is developed based on the costs incurred due to the raw materials, the work-in-process between workstations, and the finished goods. Optimal number of raw material orders that minimizes the total cost is obtained, which is then used to find the optimal number of kanbans, finished goods shipments, and the batch sizes for shipments. Numerical examples are used to demonstrate the computations of optimal parameters, and to configure the kanban mechanism on a timescale. Several avenues for future research are also indicated.     

Balancing modular transfer lines with serial-parallel activation of spindle heads at stations

The paper deals with an as yet unexplored combinatorial optimization problem concerning balancing complex transfer lines in the machining/process environment. In contrast to similar problems for assembly lines, in transfer line balancing, tasks are grouped into blocks. All tasks of each block are executed simultaneously (in parallel) by one piece of equipment (spindle head). For the transfer lines considered in this paper, spindle heads at each station are activated in serial-parallel order. The set of all available spindle heads is known beforehand. Precedence, cycle time, compatibility, and parallelism constraints for the blocks and tasks are given. The line investment cost is estimated by the sum of block and station costs. The problem is to assign all tasks (using the available blocks) such that all constraints are respected and line investment cost is at a minimum. This paper focuses on solving the problem via a branch-and-bound algorithm. An approach for obtaining an efficient lower bound is offered, based on a reduction of the initial problem to a set partitioning problem. Computational experiments reveal that the proposed approach is efficient mathematically and can be used to solve practical transfer line design problems of a medium size.     

An Operational Strategy for Throughput Maximization and Bottleneck Control in an Assembly Line System: By Selection of the Processing Rates

In this paper, an optimal operational strategy is developed to optimize the system utilization while controlling the bottleneck problem in a finite capacity integrated assembly line system (consisting of a set of tandem workstations, a set of inspection stations, a loading station and an unloading station, linked by a set of transporter stations). To develop the proposed operational strategy, a stochastic optimization model is developed for selecting the optimal processing rates of the workstations and the transporter stations, such that the total throughput rate from the system is maximized while the resulting probability of finding either a workstation or a transporter station blocked is sufficiently close to zero.     

A pegging approach to the precedence-constrained knapsack problem

The knapsack problem (KP) is generalized to the case where items are partially ordered through a set of precedence relations. As in ordinary KPs, each item is associated with profit and weight, the knapsack has a fixed capacity, and the problem is to determine the set of items to be packed in the knapsack. However, each item can be accepted only when all the preceding items have been included in the knapsack. The knapsack problem with these additional constraints is referred to as the precedence-constrained knapsack problem (PCKP). To solve PCKP exactly, we present a pegging approach, where the size of the original problem is reduced by applying the Lagrangian relaxation followed by a pegging test. Through this approach, we are able to solve PCKPs with thousands of items within a few minutes on an ordinary workstation.     

无重叠区的双抓钩周期性排序问题的求解

在当今的自动化制造系统中，计算机控制的抓钩的排序直接影响系统的生产率。本文研究了产品在系统的一边装载、而在另一边卸载的电镀线周期性排序问题。工件在每个工作站的处理时间在给定时间范围内，工作站之间没有缓冲槽，相同轨道上的两个抓钩用于工作站之间工件的运送，目标是对运送进行排序以极小化生产周期。为了求解这个问题，本文提出一个求解方法，所提出的方法首先将生产线分为两个无重叠的区域，并且为每个区域分配一个抓钩，然后，提出了一个给定抓钩分配下的混合整数线性规划模型。通过求解不同抓钩分配下模型的最优解，并且选择这些解中最好的一个，以便得到最优解，一个标杆示例被运行，以表明该方法的应用。另外，给出有多重处理槽工序问题的模型和求解方法。     

混流装配线平衡问题的多目标优化方法研究

针对混流装配线存在的工序作业多、平衡难度大等问题,以U型布置的混装线为研究对象,兼顾工作站平均负荷和瞬时负荷平衡,在最小化工作站数的基础上均衡了工作站间和工作站内不同产品的作业负荷,建立U型混流装配线多目标平衡优化模型,同时提出目标法解决联合目标中的目标函数兼容性问题。设计并运用改进的自适应遗传算法求解模型,考虑到交叉、变异操作的随机性,在变异阶段加入强制规则,并对新生成的子代个体进行基因冲突检测,以提高可行解的比率。算例研究的结果表明本文所提的多目标优化方法能够较好地解决混装线平衡问题。     

An linear programming based lower bound for the simple assembly line balancing problem

The simple assembly line balancing problem is a classical integer programming problem in operations research. A set of tasks, each one being an indivisible amount of work requiring a number of time units, must be assigned to workstations without exceeding the cycle time. We present a new lower bound, namely the LP relaxation of an integer programming formulation based on Dantzig–Wolfe decomposition. We propose a column generation algorithm to solve the formulation. Therefore, we develop a branch-and-bound algorithm to exactly solve the pricing problem. We assess the quality of the lower bound by comparing it with other lower bounds and the best-known solution of the various instances from the literature. Computational results show that the lower bound is equal to the best-known objective function value for the majority of the instances. Moreover, the new LP based lower bound is able to prove optimality for an open problem.     

Exact solution procedures for the balanced unidirectional cyclic layout problem

In this paper, we consider the balanced unidirectional cyclic layout problem (BUCLP) arising in the determination of workstation locations around a closed loop conveyor system, in the allocation of cutting tools on the sites around a turret, in the positioning of stations around a unidirectional single loop AGV path. BUCLP is known to be NP-Complete. One important property of this problem is the balanced material flow assumption where the material flow is conserved at every workstation. We first develop a branch-and-bound procedure by using the special material flow property of the problem. Then, we propose a dynamic programming algorithm, which provides optimum solutions for instances with up to 20 workstations due to memory limitations. The branch and bound procedure can solve problems with up to 50 workstations.     

A dispatching rule-based approach to production scheduling in a printed circuit board manufacturing system

This paper focuses on a production-scheduling problem in a printed circuit board (PCB) manufacturing system that produces multiple product types with different due dates and different manufacturing processes. In the PCB manufacturing system, there is a number of serial workstations, and there are multiple parallel machines at each workstation. Also, setup operations are required at certain workstations or machines, and some product types have re-entrant flows. We develop new dispatching rules for scheduling at each workstation, considering the special features of PCB manufacturing. With the dispatching rules, we determine not only the start time of each lot at a machine but also the batch size of each product at each machine. Simulation experiments are carried out to test the performance of the production-scheduling method and dispatching rules devised in this study. Results show that the production-scheduling method suggested in this study performs better than methods with well-known dispatching rules and heuristic algorithms for lot sizing in terms of the total tardiness of orders.     

A Decomposition Method for Transfer Line Life Cycle Cost Optimisation

A new method to search best parameters of a transfer line so that the cost of each manufactured part will be minimised. The synchronised transfer lines with parallel machining are considered. Such lines are widely used in mass and large-scale mechanical production. The objective is to minimise the line life cycle cost per part under the given productivity and technological constraints. The design decisions to be optimised are: number of spindles and workstations. This will be accomplished by defining subsets of tasks which are performed by one spindle head and cutting conditions for each spindle. The paper focuses on a mathematical model of the problem and methods used to solve it. This model is formulated in terms of mixed (discrete and non-linear) programming and graph theory. A special decomposition scheme based on the parametric decomposition technique is proposed. For solving the sub-problems obtained after decomposition, a Branch-and-Bound algorithm as well as a shortest path technique are used.     

Flow-shop scheduling with setup and assembly operations

A scheduling model for a production system including machining, setup and assembly operations is considered. Production of a number of single-item products is ordered. Each product is made by assembling a set of several different parts. First, the parts are manufactured in a flow-shop consisting of multiple machines. Then, they are assembled into products on a single assembly stage. Setup operation and setup time are needed when a machine starts processing the parts or it changes items. The operations are partitioned into several blocks. Each block consists of the machining operations, the setup operations, and the assembly operation(s) for one or several products. The parts of the same item in a block are processed successively. The objective function is the mean completion time for all products. We consider a problem to partition the operations into blocks and sequence the parts in each block so as to minimize the objective function. Solution procedures using pseudo-dynamic programming and a branch-and-bound method are proposed. Computational experiments are carried out to evaluate the performance of the solution procedures. It has been found that a good near-optimal schedule is obtained efficiently by the proposed solution procedures.     

Exact analysis of a two-workstation one-buffer flow line with parallel unreliable machines

This paper examines a model of a serial flow line with two workstations and an intermediate buffer. Each workstation consists of multiple unreliable parallel machines which are not necessarily identical, viz., the processing times, failure times and repair times of the parallel machines at each workstation are assumed to be exponentially distributed with non-identical mean rates. The system under consideration is solved via exact Markovian analysis. More specifically, a recursive algorithm that generates the transition matrix for any value of the intermediate buffer capacity is developed and all possible transition equations are derived and solved analytically. Once the transition equations are solved the performance measures of the model under consideration can be easily evaluated. This model may be used as a decomposition block for solving larger flow lines with parallel unreliable machines at each workstation.     

The stochastic generalized bin packing problem

The Generalized Bin Packing Problem (GBPP) is a recently introduced packing problem where, given a set of bins characterized by volume and cost and a set of items characterized by volume and profit (which also depends on bins), we want to select a subset of items to be loaded into a subset of bins which maximizes the total net profit, while satisfying the volume and bin availability constraints. The total net profit is given by the difference between the total profit of the loaded items and the total cost of the used bins. In this paper, we consider the stochastic version of the GBPP (S-GBPP), where the item profits are random variables to take into account the profit oscillations due to the handling operations for bin loading. The probability distribution of these random variables is assumed to be unknown. By using the asymptotic theory of extreme values a deterministic approximation for the S-GBPP is derived.     

Dynamic task assignment for throughput maximization with worksharing

The traditional assembly line balancing problem involves assigning a set of partially precedence constrained tasks to workstations to maximize efficiency. Each task is assigned to a unique workstation. The case is considered where task sequences are known but the workforce is partially cross-trained and some tasks can alternate between workstations. The flexibility afforded by cross-training allows the line balance to improve. Task times are allowed to be random and small buffers are allowed between workstations. Decision rules are developed and tested for various levels of cross-training between adjacent workers. Cross-training is shown to have significant impact on throughput and easy to administer rules are proven to be effective. The number of decision points for deciding to hold or pass a unit of product is also shown to be important.     

Optimal Control of a Stochastic Assembly Production Line

The system under consideration comprises n workstations in parallel and one assembly workstation. The workstations are either reliable or unreliable and the product demand is random. The n different type parts are processed first in the parallel workstations and then are joined in the assembly workstation. By minimizing the expected discounted cost, it is shown that the optimal control policy is of the bang–bang type and can be described by a set of switching manifolds. The structural properties of the optimal policy, such as monotonicity and asymptotic behavior, are investigated. These structural properties are very useful to find the optimal policy in large-size systems. Three numerical examples are given to demonstrate the results.