Balancing and Sequencing of Mixed Model Assembly Lines

Assembly lines are cost efficient production systems that mass produce identical products. Due to customer demand, manufacturers use mixed model assembly lines to produce customized products that are not identical. To stay efficient, management decisions for the line such as number of workers and assembly task assignment to stations need to be optimized to increase throughput and decrease cost. In each station, the work to be done depends on the exact product configuration, and is not consistent across all products. In this dissertation, a mixed model line balancing integer program (IP) that considers parallel workers, zoning, task assignment, and ergonomic constraints with the objective of minimizing the number of workers is proposed. Upon observing the limitation of the IP, a Constraint Programming (CP) model that is based on CPLEX CP Optimizer is developed to solve larger assembly line balancing problems. Data from an automotive OEM are used to assess the performance of both the MIP and CP models. Using the OEM data, we show that the CP model outperforms the IP model for bigger problems. A sensitivity analysis is done to assess the cost of enforcing some of the constraint on the computation complexity and the amount of violations to these constraints once they are disabled. Results show that some of the constraints are helpful in reducing the computation time. Specifically, the assignment constraints in which decision variables are fixed or bounded result in a smaller search space. Finally, since the line balance for mixed model is based on task duration averages, we propose a mixed model sequencing model that minimize the number of overload situation that might occur due to variability in tasks times by providing an optimal production sequence. We consider the skip-policy to manage overload situations and allow interactions between stations via workers swimming. An IP model formulation is proposed and a GRASP solution heuristic is developed to solve the problem. Data from the literature are used to assess the performance of the developed heuristic and to show the benefit of swimming in reducing work overload situations

Modeling and Solution Methodologies for Mixed-Model Sequencing in Automobile Industry

The global competitive environment leads companies to consider how to produce high-quality products at a lower cost. Mixed-model assembly lines are often designed such that average station work satisfies the time allocated to each station, but some models with work-intensive options require more than the allocated time. Sequencing varying models in a mixed-model assembly line, mixed-model sequencing (MMS), is a short-term decision problem that has the objective of preventing line stoppage resulting from a station work overload. Accordingly, a good allocation of models is necessary to avoid work overload. The car sequencing problem (CSP) is a specific version of the MMS that minimizes work overload by controlling the sequence of models. In order to do that, CSP restricts the number of work-intensive options by applying capacity rules. Consequently, the objective is to find the sequence with the minimum number of capacity rule violations. In this dissertation, we provide exact and heuristic solution approaches to solve different variants of MMS and CSP. First, we provide five improved lower bounds for benchmark CSP instances by solving problems optimally with a subset of options. We present four local search metaheuristics adapting efficient transformation operators to solve CSP. The computational experiments show that the Adaptive Local Search provides a significant advantage by not requiring tuning on the operator weights due to its adaptive control mechanism. Additionally, we propose a two-stage stochastic program for the mixed-model sequencing (MMS) problem with stochastic product failures, and provide improvements to the second-stage problem. To tackle the exponential number of scenarios, we employ the sample average approximation approach and two solution methodologies. On one hand, we develop an L-shaped decomposition-based algorithm, where the computational experiments show its superiority over solving the deterministic equivalent formulation with an off-the-shelf solver. We also provide a tabu search algorithm in addition to a greedy heuristic to tackle case study instances inspired by our car manufacturer partner. Numerical experiments show that the proposed solution methodologies generate high-quality solutions by utilizing a sample of scenarios. Particularly, a robust sequence that is generated by considering car failures can decrease the expected work overload by more than 20\% for both small- and large-sized instances. To the best of our knowledge, this is the first study that considers stochastic failures of products in MMS. Moreover, we propose a two-stage stochastic program and formulation improvements for a mixed-model sequencing problem with stochastic product failures and integrated reinsertion process. We present a bi-objective evolutionary optimization algorithm, a two-stage bi-objective local search algorithm, and a hybrid local search integrated evolutionary optimization algorithm to tackle the proposed problem. Numerical experiments over a case study show that while the hybrid algorithm provides a better exploration of the Pareto front representation and more reliable solutions in terms of waiting time of failed vehicles, the local search algorithm provides more reliable solutions in terms of work overload objective. Finally, dynamic reinsertion simulations are executed over industry-inspired instances to assess the quality of the solutions. The results show that integrating the reinsertion process in addition to considering vehicle failures can keep reducing the work overload by around 20\% while significantly decreasing the waiting time of the failed vehicles

Exact and heuristic procedures for the Heijunka-flow shop scheduling problem with minimum makespan and job replicas

In this paper, a new problem of job sequences in a workshop is presented, taking into account non-unit demands for the jobs and whose objective is to minimize the total completion time for all the jobs (Cmax) satisfying a set of restrictions imposed on the problem to preserve the production mix. Two procedures are proposed to solve the new problem: Mixed Integer Linear Programming and a Metaheuristic based on Multistart and Local Search. The two proposed procedures are tested using instance set Nissan-9Eng.I, in both cases giving rise to highly satisfactory performance both in quality of solutions obtained and in the CPU times required. Through a case study of the Nissan engine manufacturing plant in Barcelona, our economic-productive analysis reveals that it is possible to save an average of € 1162.83 per day, manufacturing 270 engines, when we transform the current assembly line into a Heijunka-Flow Shop.Peer ReviewedPostprint (published version

AIRO 2016. 46th Annual Conference of the Italian Operational Research Society. Emerging Advances in Logistics Systems Trieste, September 6-9, 2016 - Abstracts Book

The AIRO 2016 book of abstract collects the contributions from the conference participants. The AIRO 2016 Conference is a special occasion for the Italian Operations Research community, as AIRO annual conferences turn 46th edition in 2016. To reflect this special occasion, the Programme and Organizing Committee, chaired by Walter Ukovich, prepared a high quality Scientific Programme including the first initiative of AIRO Young, the new AIRO poster section that aims to promote the work of students, PhD students, and Postdocs with an interest in Operations Research. The Scientific Programme of the Conference offers a broad spectrum of contributions covering the variety of OR topics and research areas with an emphasis on “Emerging Advances in Logistics Systems”. The event aims at stimulating integration of existing methods and systems, fostering communication amongst different research groups, and laying the foundations for OR integrated research projects in the next decade. Distinct thematic sections follow the AIRO 2016 days starting by initial presentation of the objectives and features of the Conference. In addition three invited internationally known speakers will present Plenary Lectures, by Gianni Di Pillo, Frédéric Semet e Stefan Nickel, gathering AIRO 2016 participants together to offer key presentations on the latest advances and developments in OR’s research

3D-in-2D Displays for ATC.

This paper reports on the efforts and accomplishments of the 3D-in-2D Displays for ATC project at the end of Year 1. We describe the invention of 10 novel 3D/2D visualisations that were mostly implemented in the Augmented Reality ARToolkit. These prototype implementations of visualisation and interaction elements can be viewed on the accompanying video. We have identified six candidate design concepts which we will further research and develop. These designs correspond with the early feasibility studies stage of maturity as defined by the NASA Technology Readiness Level framework. We developed the Combination Display Framework from a review of the literature, and used it for analysing display designs in terms of display technique used and how they are combined. The insights we gained from this framework then guided our inventions and the human-centered innovation process we use to iteratively invent. Our designs are based on an understanding of user work practices. We also developed a simple ATC simulator that we used for rapid experimentation and evaluation of design ideas. We expect that if this project continues, the effort in Year 2 and 3 will be focus on maturing the concepts and employment in a operational laboratory settings

NASA space station automation: AI-based technology review

Research and Development projects in automation for the Space Station are discussed. Artificial Intelligence (AI) based automation technologies are planned to enhance crew safety through reduced need for EVA, increase crew productivity through the reduction of routine operations, increase space station autonomy, and augment space station capability through the use of teleoperation and robotics. AI technology will also be developed for the servicing of satellites at the Space Station, system monitoring and diagnosis, space manufacturing, and the assembly of large space structures

Fourth Annual Workshop on Space Operations Applications and Research (SOAR 90)

The proceedings of the SOAR workshop are presented. The technical areas included are as follows: Automation and Robotics; Environmental Interactions; Human Factors; Intelligent Systems; and Life Sciences. NASA and Air Force programmatic overviews and panel sessions were also held in each technical area

Fuelling the zero-emissions road freight of the future: routing of mobile fuellers

The future of zero-emissions road freight is closely tied to the sufficient availability of new and clean fuel options such as electricity and Hydrogen. In goods distribution using Electric Commercial Vehicles (ECVs) and Hydrogen Fuel Cell Vehicles (HFCVs) a major challenge in the transition period would pertain to their limited autonomy and scarce and unevenly distributed refuelling stations. One viable solution to facilitate and speed up the adoption of ECVs/HFCVs by logistics, however, is to get the fuel to the point where it is needed (instead of diverting the route of delivery vehicles to refuelling stations) using "Mobile Fuellers (MFs)". These are mobile battery swapping/recharging vans or mobile Hydrogen fuellers that can travel to a running ECV/HFCV to provide the fuel they require to complete their delivery routes at a rendezvous time and space. In this presentation, new vehicle routing models will be presented for a third party company that provides MF services. In the proposed problem variant, the MF provider company receives routing plans of multiple customer companies and has to design routes for a fleet of capacitated MFs that have to synchronise their routes with the running vehicles to deliver the required amount of fuel on-the-fly. This presentation will discuss and compare several mathematical models based on different business models and collaborative logistics scenarios