Sequencing mixed-model assembly lines: Survey,classification and model critique

Manufacturers in a wide range of industries nowadays face the challenge of providing a rich product variety at a very low cost. This typically requires the implementation of cost efficient, flexible production systems. Often, so called mixed-model assembly lines are employed, where setup operations are reduced to such an extent that various models of a common base product can be manufactured in intermixed sequences. However, the observed diversity of mixed-model lines makes a thorough sequence planning essential for exploiting the benefits of assembly line production. This paper reviews and discusses the three major planning approaches presented in the literature, mixed-model sequencing, car sequencing and level scheduling, and provides a hierarchical classification scheme to systematically record the academic efforts in each field and to deduce future research issues.     

A scatter search based hyper-heuristic for sequencing a mixed-model assembly line

We address a mixed-model assembly-line sequencing problem with work overload minimization criteria. We consider time windows in work stations of the assembly line (closed stations) and different versions of a product to be assembled in the line, which require different processing time according to the work required in each work station. In a paced assembly line, products are feeded in the line at a predetermined constant rate (cycle time). Then, if many products with processing time greater than cycle time are feeded consecutively, work overload can be produced when the worker has insufficient time to finish his/her job. We propose a scatter search based hyper-heuristic for this NP-hard problem. In the low-level, the procedure makes use of priority rules through a constructive procedure. Computational experiments over a wide range of instances from the literature show the effectiveness of the proposed hyper-heuristics when compared to existing heuristics. The relevance of the priority rules was evaluated as well.     

A Note on the Relation between the Product Rate Variation (PRV) Problem and the Apportionment Problem

This note establishes a connection between two problems that appear in different contexts: the Product Rate Variation (PRV) problem (sequencing units in a mixed-model assembly line in order to maximize the regularity of the sequence with regard to the output of units) and the apportionment problem. This allows us to apply to the PRV problem the properties of the apportionment problem and known procedures for solving it, and suggests alternative approaches to the former problem.     

Scheduling just-in-time part supply for mixed-model assembly lines

With increasing cost competition and product variety, providing an efficient just-in-time (JIT) supply has become one of the greatest challenges in the use of mixed-model assembly line production systems. In the present paper, therefore, we propose a new approach for scheduling JIT part supply from a central storage center. Usually, materials are stored in boxes that are allotted to the consumptive stations of the line by a forklift. For such a real-world problem, a new model, a complexity proof as well as different exact and heuristic solution procedures are provided. Furthermore, a direct comparison with a simple two-bin kanban system is provided. Such a system is currently applied in the real-world industrial process that motivates our research. It becomes obvious that this policy is considerably outperformed according to the resulting inventory- and α-service levels. Moreover, at the interface between logistics and assembly operations, strategic management implications are obtained. Specifically, based on the new approach, it is the first time a statistical analysis is being made as to whether widespread Level Scheduling policies, which are well-known from the Toyota Production System, indeed facilitate material supply. Note that in the literature it is frequently claimed that this causality exists.     

Solving the response time variability problem by means of a genetic algorithm

The response time variability problem (RTVP) is a hard scheduling problem that has recently been defined in the literature and has a wide range of real-world applications in mixed-model assembly lines, multithreaded computer systems, network environments and others. The RTVP arises whenever products, clients or jobs need to be sequenced in such a way that the variability in the time between the points at which they receive the necessary resources is minimized. Since the RTVP is a complex problem, heuristic and metaheuristic techniques are needed to solve it. The best results in the literature for the RTVP have been obtained with a psychoclonal algorithm. We propose a genetic algorithm (GA) that is adapted to solve the RTVP. A computational experiment is carried out and it is shown that, on average, the GA produces better results than the psychoclonal algorithm.     

Resequencing of mixed-model assembly lines: Survey and research agenda

Nowadays, mixed-model assembly lines are applied in a wide range of industries to mass-produce customized products to order, e.g., in automobile industry. An important decision problem in this context receiving a lot of attention from researchers and practitioners is the sequencing problem, which decides on the succession of workpieces launched down the line. However, if multiple departments with diverging sequencing objectives are to be passed or unforeseen disturbances like machine breakdowns or material shortages occur, a resequencing of a given production sequence often becomes equally essential. This paper reviews existing research on resequencing in a mixed-model assembly line context. Important problem settings, alternative buffer configurations, and resulting decision problems are described. Finally, future research needs are identified as some relevant real-world resequencing settings have not been dealt with in literature up to now.     

An adaptive search for the response time variability problem

The Response Time Variability Problem (RTVP) is an NP-hard combinatorial scheduling problem, which has recently been reported and formalised in the literature. This problem has a wide range of real-world applications in mixed-model assembly lines, multi-threaded computer systems, broadcast of commercial videotapes and others. The RTVP arises whenever products, clients or jobs need to be sequenced in such a way that the variability in the time between the points at which they receive the necessary resources is minimised. We propose a greedy but adaptive heuristic that avoids being trapped into a poor solution by incorporating a look ahead strategy suitable for this particular scheduling problem. The proposed heuristic outperforms the best existing methods, while being much faster and easier to understand and to implement.     

Car sequencing versus mixed-model sequencing: A computational study

The paper deals with the two most important mathematical models for sequencing products on a mixed-model assembly line in order to minimize work overload the mixed-model sequencing (MMS) model and the car sequencing (CS) model. Although both models follow the same underlying objective, only MMS directly addresses the work overload in its objective function. CS instead applies a surrogate objective using so-called sequencing rules which restrict labor-intensive options accompanied with the products in the sequence. The CS model minimizes the number of violations of the respective sequencing rules, which is widely assumed to lead to minimum work overload. This paper experimentally compares CS with MMS in order to quantify the gap in the solution quality between both models. The paper studies several variants of CS with different sequencing rule generation approaches and different objective functions from the literature as well as a newly introduced weighting factor. The performance of the different models is evaluated on a variety of random test instances. Although the objectives of CS and MMS are positively linearly correlated, results show that a sequence found by CS leads to at least 15% more work overload than a solution found by MMS. For none of the considered test instances and for none of the three different objective functions, CS is able to produce competitive results in terms of solution quality (work overload) compared to MMS. The results suggest that decision makers using CS should investigate whether MMS would lead to better sequencing orders for their specific instances.     

Bicriteria sequencing methods for the mixed-model assembly line in just-in-time production systems

A mixed-model manufacturing facility operating in a pull production environment can be controlled by setting a production schedule only for the last process in the facility which is usually an assembly line of mixed-model type. In the mixed-model sequencing problems, two major goals are considered: (1) smoothing the workload on each workstation on the assembly line, and (2) keeping a constant rate of usage of all parts used on the assembly line. In this study, first, some well-known solution approaches with goal 2 are analyzed through minimizing the sum-of-deviations of actual production from the desired amount. The approaches that are found to be performing better than the others are extended for the bicriteria problem considering goals 1 and 2, simultaneously. It is also shown that the bicriteria problem with the sum-of-deviations type objective function can also be formulated as an assignment problem, and the optimal solution to the small-sized problems can thus be obtained by solving the assignment problem. Finally, the conditions when it is important to take the workload-smoothing goal into consideration are analyzed.     

A survey on problems and methods in generalized assembly line balancing

Assembly lines are traditional and still attractive means of mass and large-scale series production. Since the early times of Henry Ford several developments took place which changed assembly lines from strictly paced and straight single-model lines to more flexible systems including, among others, lines with parallel work stations or tasks, customer-oriented mixed-model and multi-model lines, U-shaped lines as well as unpaced lines with intermediate buffers.In any case, an important decision problem, called assembly line balancing problem, arises and has to be solved when (re-) configuring an assembly line. It consists of distributing the total workload for manufacturing any unit of the product to be assembled among the work stations along the line.Assembly line balancing research has traditionally focused on the simple assembly line balancing problem (SALBP) which has some restricting assumptions. Recently, a lot of research work has been done in order to describe and solve more realistic generalized problems (GALBP). In this paper, we survey the developments in GALBP research.     

Modelling and solving the production rate variation problem (PRVP)

Several families of objective functions for the PRV problem (minimizing the variation in the rate at which different products are produced on an assembly line) are formalized, relationships between them are established and it is demonstrated that, in very general conditions, they can be optimized by solving an assignment problem or a polynomially bounded sequence of assignment problems.     

Shortest-route formulation of mixed-model assembly line balancing problem

A shortest-route formulation of the mixed-model assembly line balancing problem is presented. Common tasks across models are assumed to exist and these tasks are performed in the same stations. The formulation is based on an algorithm which solves the single-model version of the problem. The mixed-model system is transformed into a single-model system with a combined precedence diagram. The model is capable of considering any constraint that can be expressed as a function of task assignments.     

Solving the car sequencing problem via Branch & Bound

In a mixed-model assembly line, varying models of the same basic product are to be produced in a facultative sequence. This results to a short-term planning problem where a sequence of models is sought which minimizes station overloads. In practice – e.g. the final assembly of cars – special sequencing rules are enforced which restrict the number of models possessing a certain optional feature k to r_k within a subsequence of s_k successive models. This problem is known as car sequencing. So far, employed solution techniques stem mainly from the field of Logic and Constraint Logic Programming. In this work, a special Branch & Bound algorithm is developed, which exploits the problem structure in order to reduce combinatorial complexity.     

Pattern Based Vocabulary Building for Effectively Sequencing Mixed-Model Assembly Lines

In this paper, the problem of sequencing mixed-model assembly lines in case of fixed rate launching and closed stations is considered. The problem consists of finding an intermixed sequence of different models of a basic product, which are jointly produced on an assembly line, such that customer demands are fulfilled and total work overload is minimized. For solving this problem an informed tabu search procedure with a pattern based vocabulary building strategy is developed. Computational tests demonstrate that considerable improvements are obtained by comparison to methods which do not incorporate such an approach.     

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。     

Perturbation Stability of Coherent Riesz Systems under Convolution Operators

We study the orthogonal perturbation of various coherent function systems (Gabor systems, Wilson bases, and wavelets) under convolution operators. This problem is of key relevance in the design of modulation signal sets for digital communication over time-invariant channels. Upper and lower bounds on the orthogonal perturbation are formulated in terms of spectral spread and temporal support of the prototype, and by the approximate design of worst-case convolution kernels. Among the considered bases, the Weyl–Heisenberg structure which generates Gabor systems turns out to be optimal whenever the class of convolution operators satisfies typical practical constraints.     

Metaheuristic algorithms hybridised with variable neighbourhood search for solving the response time variability problem

The response time variability problem (RTVP) is a scheduling problem with a wide range of real-world applications: mixed-model assembly lines, multi-threaded computer systems, network environments, broadcast of commercial videotapes and machine maintenance, among others. The RTVP arises whenever products, clients or jobs need to be sequenced in such a way that the variability in the time between the points at which they receive the necessary resources is minimised. Since the RTVP is NP-hard, several heuristic and metaheuristic techniques are needed to solve non-small instances. The published metaheuristic procedure that obtained the best solutions, on average, for non-small RTVP instances is an algorithm based on a variant of the variable neighbourhood search (VNS), called Reduced VNS (RVNS). We propose hybridising RVNS with three existing algorithms based on tabu search, multi-start and particle swarm optimisation. The aim is to combine the strengths of the metaheuristics. A computational experiment is carried out and it is shown that, on average, all proposed hybrid methods are able to improve the best published solutions.     

一种类微粒群算法及其在混流装配线调度问题中的应用

混流装配生产线的调度问题是准时化生产系统中最重要的问题之一.基于微粒群算法的原理,提出了一种类微粒群算法——PPSO(Pseudo Particle Swarm Optimization),可应用于解决准时化生产方式下的混流装配线调度问题.数值试验表明,采用PPSO方法比采用目标追随法、遗传算法和模拟退火算法的求解质量有很大提高.     

Solving symmetric mixed-model multi-level just-in-time scheduling problems

The generation of leveled production schedules is of high importance for mixed-model assembly lines whose parts and materials are supplied just-in-time by multi-level production processes. The Output Rate Variation problem is the standard mathematical representation of this complex level scheduling problem and has been extensively studied by research thus far. This work identifies novel symmetries in solution sequences of this problem class and shows how these insights can be used to improve exact solution procedures presented in the literature. The effectiveness of the modifications is evaluated by a computational study.     

Modeling and analysis of a supply–assembly–store chain

We consider a supply–assembly–store chain with produce-to-stock strategy, which comprises a set of component suppliers, a mixed-model assembly line with a constantly moving conveyor linking a set of workstations in series, and a set of product storehouses. Each supplier provides components of a specified family, which are assembled at a corresponding workstation. Units belonging to different models of products are sequentially fed onto the conveyor, and pass through the workstations to generate finished products. Each storehouse stores finished products belonging to a specific model for satisfying customer demands. The suppliers deliver components according to a just-in-time supply policy with stochastic leadtimes. Customer demands for a particular model of products arrive at the corresponding storehouse according to a Poisson stream. The paper conducts a modeling and performance analysis in the design stage of the system in the sense of “long-term-behavior”. A rolling technique is constructed for analyzing stationary probability distributions of the numbers of components. A two-dimensional Markov chain with infinite states is introduced for analyzing stationary probability distributions of inventories of finished products. Based on these distributions, performance measures of the system, such as work-in-process of components, inventory amounts of finished products, as well as service levels for customers, can be easily obtained. Managerial insights are obtained from both analytical and numerical results.