Balancing and scheduling tasks in assembly lines with sequence-dependent setup times

The classical Simple Assembly Line Balancing Problem (SALBP) has been widely enriched over the past few years with many realistic approaches and much effort has been made to reduce the distance between the academic theory and the industrial reality. Despite this effort, the scheduling of the execution of tasks assigned to every workstation following the balancing of the assembly line has been scarcely reported in the scientific literature. This is supposed to be an operational concern that the worker should solve himself, but in several real environments, setups between tasks exist and optimal or near-optimal tasks schedules should be provided inside each workstation. The problem presented in this paper adds sequence-dependent setup time considerations to the classical SALBP in the following way: whenever a task is assigned next to another at the same workstation, a setup time must be added to compute the global workstation time. After formulating a mathematical model for this innovative problem and showing the high combinatorial nature of the problem, eight different heuristic rules and a GRASP algorithm are designed and tested for solving the problem in reasonable computational time.     

A hybrid approach for single-machine tardiness problems with sequence-dependent setup times

Scheduling problems in real systems often require sequence-dependent setup times. The topic of sequence-dependent setup times has not been addressed adequately, and improved competitiveness is thus not achieved. This study proposes a hybrid approach that takes advantage of simulated annealing (SA) and tabu search (TS) to solve single-machine tardiness problems with sequence-dependent setup times. To verify the proposed approach, experiments were conducted on benchmark problem sets that included both the weighted and un-weighted tardiness problems. The results show that the performance of the hybrid approach is superior to that of the SA, genetic algorithm, TS and ant colony optimization approaches, and is comparable with the Tabu-VNS approach. And the proposed approach found new upper bound values for many benchmark problems with an acceptable computational time.     

Carryover sequence-dependent group scheduling with the integration of internal and external setup times

This paper addresses a group scheduling problem in a two-machine flow shop with a bicriteria objective and carryover sequence-dependent setup times. This special type of group scheduling problem typically arises in the assembly of printed circuit boards (PCBs). The objective is to sequence all board types in a board group as well as board groups themselves in a way that the objective function is minimized. We introduce the carryover sequence-dependent setup on machines, and call it internal setup. As an opportunity for manufacturers to decrease the costs, the focus is to completely eliminate the role of the kitting staff. Thus, we introduce the external setup (kitting) time for the next board group and require it to be performed by the machine operator during the time he is idle. Consequently, the internal and external setup times are integrated in this research, and to the best of our knowledge it is for the first time a research on PCB group scheduling is performed by integrating both setups. In order to solve this problem, first a mathematical model is developed. Then a heuristic together with two other meta-heuristic algorithms (one based on tabu search and the other based on genetic algorithm) are proposed and their efficiency and effectiveness on several problems are tested. Also a statistical experimental design is performed in order to evaluate the impact of different factors on the performance of the algorithms.     

Balancing stochastic two-sided assembly lines: A chance-constrained,piecewise-linear,mixed integer program and a simulated annealing algorithm

Two-sided assembly lines are often designed to produce large-sized products, such as automobiles, trucks and buses. In this type of a production line, both left-side and right-side of the line are used in parallel. In all studies on two-sided assembly lines, the task times are assumed to be deterministic. However, in real life applications, especially in manual assembly lines, the tasks may have varying execution times defined as a probability distribution. The task time variation may result from machine breakdowns, loss of motivation, lack of training, non-qualified operators, complex tasks, environment, etc. In this paper, the problem of balancing two-sided assembly lines with stochastic task times (STALBP) is considered. A chance-constrained, piecewise-linear, mixed integer program (CPMIP) is proposed to model and solve the problem. As a solution approach a simulated annealing (SA) algorithm is proposed. To assess the effectiveness of CPMIP and SA algorithm, a set of test problems are solved. Finally, computational results indicating the effectiveness of CPMIP and SA algorithm are reported.     

A search heuristic for the sequence-dependent economic lot scheduling problem

Almost all of the research on the economic lot scheduling problem (ELSP) has assumed that setup times are sequence-independent even though sequence-dependent problems are common in practice. Furthermore, most of the solution approaches that have been developed solve for a single optimal schedule when in practice it is more important to provide managers with a range of schedules of different length and complexity. In this paper, we develop a heuristic procedure to solve the ELSP problem with sequence-dependent setups. The heuristic provides a range of solutions from which a manager can choose, which should prove useful in an actual stochastic production environment. We show that our heuristic can outperform Dobson's heuristic when the utilization is high and the sequence-dependent setup times and costs are significant.     

A decomposition approach for the General Lotsizing and Scheduling Problem for Parallel production Lines

This paper presents a novel solution heuristic to the General Lotsizing and Scheduling Problem for Parallel production Lines (GLSPPL). The GLSPPL addresses the problem of simultaneously deciding about the sizes and schedules of production lots on parallel, heterogeneous production lines with respect to scarce capacity, sequence-dependent setup times and deterministic, dynamic demand of multiple products. Its objective is to minimize inventory holding, sequence-dependent setup and production costs. The new heuristic iteratively decomposes the multi-line problem into a series of single-line problems, which are easier to solve. Different approaches for decomposition and for the iteration between a modified multi-line master problem and the single-line subproblems are proposed. They are compared with an existing solution method for the GLSPPL by means of medium-sized and large practical problem instances from different types of industries. The new methods prove to be superior with respect to both solution quality and computation time.     

A hybrid genetic algorithm for sequence-dependent disassembly line balancing problem

For remanufacturing or recycling companies, a reverse supply chain is of prime importance since it facilitates in recovering parts and materials from end-of-life products. In reverse supply chains, selective separation of desired parts and materials from returned products is achieved by means of disassembly which is a process of systematic separation of an assembly into its components, subassemblies or other groupings. Due to its high productivity and suitability for automation, disassembly line is the most efficient layout for product recovery operations. A disassembly line must be balanced to optimize the use of resources (viz., labor, money and time). In this paper, we consider a sequence-dependent disassembly line balancing problem (SDDLBP) with multiple objectives that requires the assignment of disassembly tasks to a set of ordered disassembly workstations while satisfying the disassembly precedence constraints and optimizing the effectiveness of several measures considering sequence dependent time increments. A hybrid algorithm that combines a genetic algorithm with a variable neighborhood search method (VNSGA) is proposed to solve the SDDLBP. The performance of VNSGA was thoroughly investigated using numerous data instances that have been gathered and adapted from the disassembly and the assembly line balancing literature. Using the data instances, the performance of VNSGA was compared with the best known metaheuristic methods reported in the literature. The tests demonstrated the superiority of the proposed method among all the methods considered.     

Minimizing sum of completion times on a single machine with sequence-dependent family setup times

This paper presents a branch-and-bound (B&B) algorithm for minimizing the sum of completion times in a single-machine scheduling setting with sequence-dependent family setup times. The main feature of the B&B algorithm is a new lower bounding scheme that is based on a network formulation of the problem. With extensive computational tests, we demonstrate that the B&B algorithm can solve problems with up to 60 jobs and 12 families, where setup and processing times are uniformly distributed in various combinations of the [1,50] and [1,100] ranges.     

Scatter search for minimizing weighted tardiness in a single machine scheduling with setups

Single machine scheduling problems have many real-life applications and may be hard to solve due to the particular characteristics of some production environments. In this paper, we tackle the single machine scheduling problem with sequence-dependent setup times with the objective of minimizing the weighted tardiness. To solve this problem, we propose a scatter search algorithm which uses path relinking in its core. This algorithm is enhanced with some procedures to speed-up the neighbors’ evaluation and with some diversification and intensification techniques, the latter taking some elements from iterated local search. We conducted an experimental study across a well-known set of instances to analyze the contribution of each component to the overall performance of the algorithm, as well as to compare our proposal with the state-of-the-art metaheuristics, obtaining competitive results. We also propose a new benchmark with larger and more challenging instances and provide the first results for them.     

Increasing the total net revenue for single machine order acceptance and scheduling problems using an artificial bee colony algorithm

The order acceptance and scheduling (OAS) problem is an important topic for make-to-order production systems with limited production capacity and tight delivery requirements. This paper proposes a new algorithm based on Artificial Bee Colony (ABC) for solving the single machine OAS problem with release dates and sequence-dependent setup times. The performance of the proposed ABC-based algorithm was validated by a benchmark problem set of test instances with up to 100 orders. Experimental results showed that the proposed ABC-based algorithm outperformed three state-of-art metaheuristic-based algorithms from the literature. It is believed that this study successfully demonstrates a high-performance algorithm that can serve as a new benchmark approach for future research on the OAS problem addressed in this study.

     

An efficient grouping genetic algorithm for U-shaped assembly line balancing problems with maximizing production rate

U-type assembly line is one of the important tools that may increase companies’ production efficiency. In this study, two different modeling approaches proposed for the assembly line balancing problems have been used in modeling type-II U-line balancing problems, and the performances of these models have been compared with each other. It has been shown that using mathematical formulations to solve medium and large size problem instances is impractical since the problem is NP-hard. Therefore, a grouping genetic and simulated annealing algorithms have been developed, and a particle swarm optimization algorithm is adapted to compare with the proposed methods. A special crossover operator that always obtains feasible offspring has been suggested for the proposed grouping genetic algorithm. Furthermore, a local search procedure based on problem-specific knowledge was applied to increase the intensification of the algorithm. A set of well-known benchmark instances was solved to evaluate the effectiveness of the proposed and existing methods. Results showed that while the mathematical formulations can only be used to solve small size instances, metaheuristics can obtain high quality solutions for all size problem instances within acceptable CPU times. Moreover, grouping genetic algorithm has been found to be superior to the other methods according to the number of optimal solutions, or deviations from the lower bound values.     

A genetic algorithm for robotic assembly line balancing

Flexibility and automation in assembly lines can be achieved by the use of robots. The robotic assembly line balancing (RALB) problem is defined for robotic assembly line, where different robots may be assigned to the assembly tasks, and each robot needs different assembly times to perform a given task, because of its capabilities and specialization. The solution to the RALB problem includes an attempt for optimal assignment of robots to line stations and a balanced distribution of work between different stations. It aims at maximizing the production rate of the line. A genetic algorithm (GA) is used to find a solution to this problem. Two different procedures for adapting the GA to the RALB problem, by assigning robots with different capabilities to workstations are introduced: a recursive assignment procedure and a consecutive assignment procedure. The results of the GA are improved by a local optimization (hill climbing) work-piece exchange procedure. Tests conducted on a set of randomly generated problems, show that the Consecutive Assignment procedure achieves, in general, better solution quality (measured by average cycle time). Further tests are conducted to determine the best combination of parameters for the GA procedure. Comparison of the GA algorithm results with a truncated Branch and Bound algorithm for the RALB problem, demonstrates that the GA gives consistently better results.     

A bicriteria m-machine flowshop scheduling with sequence-dependent setup times

In this study, a bicriteria m-machine flowshop scheduling with sequence-dependent setup times is considered. The objective function of the problem is minimization of the weighted sum of total completion time and makespan. Only small size problems with up to 6 machines and 18 jobs can be solved by the proposed integer programming model. Also the model is tested on an example. We also proposed three heuristic approaches for solving large jobs problems. To solve the large sizes problems up to 100 jobs and 10 machines, special heuristics methods is used. Results of computational tests show that the proposed model is effective in solving problems.     

Order acceptance and scheduling with earliness and tardiness penalties

This paper addresses a production scheduling problem in a single-machine environment, where a job can be either early, on time, late, or rejected. In order acceptance and scheduling contexts, it is assumed that the production capacity of a company is overloaded. The problem is therefore to decide which orders to accept and how to sequence their production. In contrast with the existing literature, the considered problem jointly takes into account the following features: earliness and tardiness penalties (which can be linear or quadratic), sequence-dependent setup times and costs, rejection penalties, and the possibility of having idle times. The practical relevance of this new NP-hard problem is discussed and various solution methods are proposed, ranging from a basic greedy algorithm to refined metaheuristics (e.g., tabu search, the adaptive memory algorithm, population-based approaches loosely inspired on ant algorithms). The methods are compared for instances with various structures containing up to 200 jobs. For small linear instances, the metaheuristics are favorably compared with an exact formulation using CPLEX 12.2. Managerial insights and recommendations are finally given.     

A branch and bound method for the job-shop problem with sequence-dependent setup times

This paper deals with the job-shop scheduling problem with sequence-dependent setup times. We propose a new method to solve the makespan minimization problem to optimality. The method is based on iterative solving via branch and bound decisional versions of the problem. At each node of the branch and bound tree, constraint propagation algorithms adapted to setup times are performed for domain filtering and feasibility check. Relaxations based on the traveling salesman problem with time windows are also solved to perform additional pruning. The traveling salesman problem is formulated as an elementary shortest path problem with resource constraints and solved through dynamic programming. This method allows to close previously unsolved benchmark instances of the literature and also provides new lower and upper bounds.     

Algorithms for common due-date assignment and sequencing on a single machine with sequence-dependent setup times

This paper focuses on the single machine sequencing and common due-date assignment problem for the objective of minimizing the sum of the penalties associated with earliness, tardiness and due-date assignment. Unlike the previous research articles on this class of scheduling problem, we consider sequence-dependent setup times that make the problem much more difficult. To solve the problem, a branch and bound algorithm, which incorporates the method to obtain lower and upper bounds as well as a dominance property to reduce the search space, is suggested that gives the optimal solutions for small-sized instances. Heuristic algorithms are suggested to obtain solutions for large-sized problems within a reasonable computation time. The performances of both the optimal and heuristic algorithms, in computational experiments on randomly generated test instances, are reported.     

Balancing assembly lines with tabu search

Balancing assembly lines is a crucial task for manufacturing companies in order to improve productivity and minimize production costs. Despite some progress in exact methods to solve large scale problems, softwares implementing simple heuristics are still the most commonly used tools in industry. Some metaheuristics have also been proposed and shown to improve on classical heuristics but, to our knowledge, no computational experiments have been performed on real industrial applications to clearly assess their performance as well as their flexibility. Here we present a new tabu search algorithm and discuss its differences with respect to those in the literature. We then evaluate its performance on the Type I assembly line balancing problem. Finally, we test our algorithm on a real industrial data set involving 162 tasks, 264 precedence constraints, and where the assembly is carried out on a sequential line with workstations located on both sides of the conveyor, with two possible conveyor heights and no re-positioning of the product. We discuss the flexibility of the metaheuristic and its ability to solve real industrial cases.     

具有工作站数量约束的多人工作站混合装配线平衡问题研究

针对装配线设计或改造过程中存在的因场地或成本原因导致的工作站数量不易变更的问题,研究了节拍已知情况下,具有工作站数量约束的多人工作站混合装配线平衡问题,建立以装配线总人数最小、工人负荷量标准差最小、各产品在各工作站装配时间与节拍之间的标准差最小为目标的数学模型,设计了一种结合差分进化的多目标混合遗传算法对该问题求解。通过案例计算以及与其他算法的对比分析表明,本文算法在收敛性和综合性能方面优于NSGAII和DEMO,在装配线人数和工人负荷标准差方面优于Roshani和Nezami提出的算法。     

Audit scheduling with overlapping activities and sequence-dependent setup costs

Audit firms are faced with the complex job of scheduling auditors to audit tasks. The scheduling becomes more complex as the firm needs to consider real life issues in determining an optimal schedule. Among these issues are the setup times and costs emanating from changing the assignments of the auditors and the lead and lag relationships between the audit tasks.Audit scheduling with overlapping activities and sequence-dependent setup cost has not been treated in literature. This paper presents a formulation and a solution approach for this audit scheduling problem. First, the problem is represented by an activity network with lead/lag relationships. Then the network is analyzed to determine the early and late finish times of activities. An integer linear program (ILP), which uses the early and late finish times of activities to reduce the number of decision variables, is formulated. A four-auditor two-engagement example is used to illustrate the ILP model and its solution. The results indicate that incorporating the setup cost and the overlapping of activities yields lower cost schedules leading to sizable savings in the cost of audits. The proposed treatment is of merit in providing realistic schedules that can be easily implemented     

Enhanced migrating birds optimization algorithm for the permutation flow shop problem with sequence dependent setup times

This paper presents an enhanced migrating bird optimization (MBO) algorithm and a new heuristic for solving a scheduling problem. The proposed approaches are applied to a permutation flowshop with sequence dependent setup times and the objective of minimizing the makespan. In order to augment the MBOs intensification capacity, an original problem specific heuristic is introduced. An adapted neighborhood, a tabu list, a restart mechanism and an original process for selecting a new leader also improved the MBO’s behavior. Using benchmarks from the literature, the resulting enhanced MBO (EMBO) gives state-of-the-art results when compared with other algorithms reference. A statistical analysis of the numerical experiments confirms the relative efficiency and effectiveness of both EMBO and the new heuristic.