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.     

Analysis and design of sequencing rules for car sequencing

This paper presents novel approaches for generating sequencing rules for the car sequencing (CS) problem in cases of two and multiple processing times per station. The CS problem decides on the succession of different car models launched down a mixed-model assembly line. It aims to avoid work overloads at the stations of the line by applying so-called sequencing rules, which restrict the maximum occurrence of labor-intensive options in a subsequence of a certain length. Thus to successfully avoid work overloads, suitable sequencing rules are essential. The paper shows that the only existing rule generation approach leads to sequencing rules which misclassify feasible sequences. We present a novel procedure which overcomes this drawback by generating multiple sequencing rules. Then, it is shown how to apply both procedures in case of multiple processing times per station. For both cases analytical and empirical results are derived to compare classification quality.     

Comments on “Solving real car sequencing problems with ant colony optimization”

This note corrects the calculation of the utilization rate in the article “Solving real car sequencing problems with ant colony optimization” by Gagné et al. [Gagné, C., Gravel, M., Price, W.L., 2006. Solving real car sequencing problems with ant colony optimization. European Journal of Operational Research 174, 1427–1448] and provides hints on deriving a fast lower bound for the car sequencing problem. It further adjusts a proposed objective function, so that it becomes a viable alternative to the “sliding window” approach.     

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 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.     

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.     

A Beam Search approach for the optimization version of the Car Sequencing Problem

The Car Sequencing Problem (CSP) is a feasibility problem that has attracted the attention of the Constraint Programming community for a number of years now. In this paper, a new version (opt-CSP) that extends the original problem is defined, converting this into an optimization problem in which the goal is to satisfy the typical hard constraints. This paper presents a solution procedure for opt-CSP using Beam Search. Computational results are presented using public instances that verify the goodness of the procedure and demonstrate its excellent performance in obtaining feasible solutions for the majority of instances while satisfying the new constraints.     

Optimally routing and scheduling tow trains for JIT-supply of mixed-model assembly lines

In recent years, more and more automobile producers adopted the supermarket-concept to enable a flexible and reliable Just-in-Time (JIT) part supply of their mixed-model assembly lines. Within this concept, a supermarket is a decentralized in-house logistics area where parts are intermediately stored and then loaded on small tow trains. These tow trains travel across the shop floor on specific routes to make frequent small-lot deliveries which are needed by the stations of the line. To enable a reliable part supply in line with the JIT-principle, the interdependent problems of routing, that is, partitioning stations to be supplied among tow trains, and scheduling, i.e., deciding on the start times of each tow train’s tours through its assigned stations, need to be solved. This paper introduces an exact solution procedure which solves both problems simultaneously in polynomial runtime. Additionally, management implications regarding the trade-off between number and capacity of tow trains and in-process inventory near the line are investigated within a comprehensive computational study.     

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.     

Scheduling the part supply of mixed-model assembly lines in line-integrated supermarkets

Line-integrated supermarkets constitute a novel in-house parts logistics concept for feeding mixed-model assembly lines. In this context, supermarkets are decentralized logistics areas located directly in each station. Here, parts are withdrawn from their containers by a dedicated logistics worker and sorted just-in-sequence (JIS) into a JIS-bin. From this bin, assembly workers fetch the parts required by the current workpiece and mount them during the respective production cycle. This paper treats the scheduling of the part supply processes within line-integrated supermarkets. The scheduling problem for refilling the JIS-bins is formalized and a complexity analysis is provided. Furthermore, a heuristic decomposition approach is presented and important managerial aspects are investigated.     

A Lagrangian relaxation approach to the mixed-product assembly line sequencing problem: A case study of a door-lock company in Taiwan

In mixed-product assembly line sequencing, the production resources required for the assembly lines should be scheduled to minimize the overall cost and meet customer demand. In this paper, we study an assembly line sequencing problem for the door-lock industry in Taiwan and develop an integer programming formulation with realistic constraints. The complex solution space makes the resulting program difficult to solve using commercial optimization packages. Therefore, a heuristic based on the Lagrangian relaxation principle is developed to solve this problem efficiently. We evaluate the efficiency of the developed Lagrangian relaxation heuristic by comparing its solutions with those obtained using a commercial optimization package: the computational results show that the developed heuristic solves the real-world problem faster than the optimization package by almost 15 times in CPU time at a comparable solution quality.     

The product rate variation problem and its relevance in real world mixed-model assembly lines

Production processes in a wide range of industries rely on modern mixed-model assembly systems, which allow an efficient manufacture of various models of a common base product on the same assembly line. In order to facilitate a just-in-time supply of materials, the literature proposes various sequencing problems under the term “level scheduling”, which all aim at evenly smoothing the part consumption induced by the production sequence over time. Among these approaches, the popular product rate variation (PRV) problem is considered to be an appropriate approximate model, if either (i) all products require approximately the same number and mix of parts or (ii) part usages of all products are (almost completely) distinct. These statements are (iii) further specified by analytical findings, which prove the equivalence of product and material oriented level scheduling under certain conditions. These three prerequisites commonly cited in the literature when justifying the practical relevance of the PRV are evaluated by means of three simple computational experiments and are then discussed with regard to their relevance in practical settings. It is concluded that the PRV is in fact inappropriate for use in today’s real world mixed-model assembly systems.     

混合型装配线平衡问题求解方法研究

对混合型装配线平衡问题进行了描述和数学建模,提出一种启发式求解算法,求解目标是最小化工作站数目.为进一步优化求解结果,对启发式算法求解的结果进行仿真研究,分析各工作站的工作率、等待率和阻塞率,并以此为依据调整部分作业任务的分配,允许不同品种产品的相同作业任务安排在不同的工作站中,以对求解结果进行修正,进一步均衡各工作站的作业量.该求解方法既简化了求解过程,又兼顾到了系统的瞬时特性和作业任务的不可拆分性对求解结果的影响,实例分析验证了方法的有效性.     

Soft car sequencing with colors: Lower bounds and optimality proofs

This paper is a study of the car sequencing problem, when feature spacing constraints are soft and colors of vehicles are taken into account. Both pseudo-polynomial algorithms and lower bounds are presented for parts of the problem or family of instances. With this set of lower bounds, we establish the optimality (up to the first non-trivial criteria) of 54% of best known solutions for the benchmark used for the Roadef Challenge 2005. We also prove that the optimal penalty for a single ratio constraint N/P can be computed in O(P) and that determining the feasibility of a car sequencing instance limited to a pair of simple ratio constraints can be achieved by dynamic programming. Finally, we propose a solving algorithm exploiting these results within a local search approach. To achieve this goal, a new meta-heuristic (star relinking) is introduced, designed for the optimization of an aggregation of criteria, when the optimization of each single criterion is a polynomial problem.     

The car sequencing problem: Overview of state-of-the-art methods and industrial case-study of the ROADEF’2005 challenge problem

The ROADEF challenge is organized every two years by the French Society of Operations Research and Decision-Making Aid. The goal is to allow industrial partners to witness recent developments in the field of Operations Research and Decision Analysis, and researchers to face up a decisional problem, often complex, occurred in industry.     

Iterated tabu search for the car sequencing problem

This paper introduces an iterated tabu search heuristic for the daily car sequencing problem in which a set of cars must be sequenced so as to satisfy requirements from the paint shop and the assembly line. The iterated tabu search heuristic combines a classical tabu search with perturbation operators that help escape from local optima. The resulting heuristic is flexible, easy to implement, and fast. It has produced very good results on a set of test instances provided by the French car manufacturer Renault.     

A hybrid heuristic for a multi-objective real-life car sequencing problem with painting and assembly line constraints

We address a multi-objective version of the car sequencing problem, which consists in sequencing a given set of cars to be produced in a single day, minimizing the number of violations of assembly constraints and the number of paint color changes in the production line. We propose a set of heuristics for approximately solving this problem, based on the paradigms of the VNS and ILS metaheuristics, to which further intensification and diversification strategies have been added. Computational results on real-life test instances are reported. The work presented in this paper obtained the second prize in the ROADEF challenge 2005 sponsored by Renault.     

A survey of surface mount device placement machine optimisation: Machine classification

The optimisation of a printed circuit board assembly line is mainly influenced by the constraints of the surface mount device (SMD) placement machine and the characteristics of the production environment. This paper surveys the characteristics of the various machine technologies and classifies them into five categories (dual-delivery, multi-station, turret-type, multi-head and sequential pick-and-place), based on their specifications and operational methods. Using this classification, we associate the machine technologies with heuristic methods and discuss the scheduling issues of each category of machine. We see the main contribution of this work as providing a classification for SMD placement machines and to survey the heuristics that have been used on different machines. We hope that this will guide other researchers so that they can subsequently use the classification or heuristics, or even design new heuristics that are more appropriate to the machine under consideration.     

Combining two pheromone structures for solving the car sequencing problem with Ant Colony Optimization

The car sequencing problem involves scheduling cars along an assembly line while satisfying capacity constraints. In this paper, we describe an Ant Colony Optimization (ACO) algorithm for solving this problem, and we introduce two different pheromone structures for this algorithm: the first pheromone structure aims at learning for “good” sequences of cars, whereas the second pheromone structure aims at learning for “critical” cars. We experimentally compare these two pheromone structures, that have complementary performances, and show that their combination allows ants to solve very quickly most instances.