An analysis of task assignment and cycle times when robots are added to human-operated assembly lines, using mathematical programming models

Abstract Adding robots to a human-operated assembly line influences both the short- and long-term operation of the line. However, the effects of robots on assembly line capacity and on cycle time can only be studied if appropriate task assignment models are available. This paper shows how traditional assembly line balancing models can be changed in order to determine the optimal number of workstations and cycle time when robots with different technological capabilities are able to perform a predetermined set of tasks. The mathematical programming models for the following three cases are presented and analysed: i) only workers are assigned to the workstations; ii) either a worker or a robot is assigned to a workstation; iii) a robot and a worker are also assigned to specific workstations. The data of an assembly line producing power inverters is used to illustrate the proposed calculations. Both the assignment of tasks and the changes of cycle time are analysed within the AIMMS modelling environment. The computational characteristics of the proposed mathematical programming models are also examined and tested using benchmark problems. The models presented in this paper can assist operations management in making decisions relating to assembly line configuration

Algorithms and Methods for Designing and Scheduling Smart Manufacturing Systems

This book, as a Special Issue, is a collection of some of the latest advancements in designing and scheduling smart manufacturing systems. The smart manufacturing concept is undoubtedly considered a paradigm shift in manufacturing technology. This conception is part of the Industry 4.0 strategy, or equivalent national policies, and brings new challenges and opportunities for the companies that are facing tough global competition. Industry 4.0 should not only be perceived as one of many possible strategies for manufacturing companies, but also as an important practice within organizations. The main focus of Industry 4.0 implementation is to combine production, information technology, and the internet. The presented Special Issue consists of ten research papers presenting the latest works in the field. The papers include various topics, which can be divided into three categories—(i) designing and scheduling manufacturing systems (seven articles), (ii) machining process optimization (two articles), (iii) digital insurance platforms (one article). Most of the mentioned research problems are solved in these articles by using genetic algorithms, the harmony search algorithm, the hybrid bat algorithm, the combined whale optimization algorithm, and other optimization and decision-making methods. The above-mentioned groups of articles are briefly described in this order in this book

Application of lean scheduling and production control in non-repetitive manufacturing systems using intelligent agent decision support

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Lean Manufacturing (LM) is widely accepted as a world-class manufacturing paradigm, its currency and superiority are manifested in numerous recent success stories. Most lean tools including Just-in-Time (JIT) were designed for repetitive serial production systems. This resulted in a substantial stream of research which dismissed a priori the suitability of LM for non-repetitive non-serial job-shops. The extension of LM into non-repetitive production systems is opposed on the basis of the sheer complexity of applying JIT pull production control in non-repetitive systems fabricating a high variety of products. However, the application of LM in job-shops is not unexplored. Studies proposing the extension of leanness into non-repetitive production systems have promoted the modification of pull control mechanisms or reconfiguration of job-shops into cellular manufacturing systems. This thesis sought to address the shortcomings of the aforementioned approaches. The contribution of this thesis to knowledge in the field of production and operations management is threefold: Firstly, a Multi-Agent System (MAS) is designed to directly apply pull production control to a good approximation of a real-life job-shop. The scale and complexity of the developed MAS prove that the application of pull production control in non-repetitive manufacturing systems is challenging, perplex and laborious. Secondly, the thesis examines three pull production control mechanisms namely, Kanban, Base Stock and Constant Work-in-Process (CONWIP) which it enhances so as to prevent system deadlocks, an issue largely unaddressed in the relevant literature. Having successfully tested the transferability of pull production control to non-repetitive manufacturing, the third contribution of this thesis is that it uses experimental and empirical data to examine the impact of pull production control on job-shop performance. The thesis identifies issues resulting from the application of pull control in job-shops which have implications for industry practice and concludes by outlining further research that can be undertaken in this direction

Design and Management of Manufacturing Systems

Although the design and management of manufacturing systems have been explored in the literature for many years now, they still remain topical problems in the current scientific research. The changing market trends, globalization, the constant pressure to reduce production costs, and technical and technological progress make it necessary to search for new manufacturing methods and ways of organizing them, and to modify manufacturing system design paradigms. This book presents current research in different areas connected with the design and management of manufacturing systems and covers such subject areas as: methods supporting the design of manufacturing systems, methods of improving maintenance processes in companies, the design and improvement of manufacturing processes, the control of production processes in modern manufacturing systems production methods and techniques used in modern manufacturing systems and environmental aspects of production and their impact on the design and management of manufacturing systems. The wide range of research findings reported in this book confirms that the design of manufacturing systems is a complex problem and that the achievement of goals set for modern manufacturing systems requires interdisciplinary knowledge and the simultaneous design of the product, process and system, as well as the knowledge of modern manufacturing and organizational methods and techniques

Desenvolvimento de algoritmo para otimização de linhas de montagem

O balanceamento de uma linha de produção tem como objetivo anular o “gargalo” de produção, promovendo o máximo de produtividade e eficiência, mantendo o ritmo de trabalho adequado do processo produtivo. Desta forma, o presente projeto foca-se na identificação e eliminação de desperdícios, melhorando os processos de montagem, mediante o estudo dos tempos de ciclo dos postos de trabalhos e as tarefas executadas por cada operador. Na análise feita à linha, é descrito o processo com todas as tarefas inerentes à montagem da cadeira porta-bebé, bem como as fotografias da instrução de trabalho e controlo que auxiliam a montagem da cadeira. De igual forma são apresentados os dados recolhidos inicialmente e a proposta de melhoria. Posto isto, foi criada uma interface com o Excel, que indica qual o número teórico de operadores necessários, dado o nº de encomendas requeridas para um determinado período de tempo. Esta interface recorre a um problema de otimização, que é resolvido com recurso do Solver para efetuar a afetação das diferentes tarefas aos operadores. A análise feita, se for implementada, poderá ter um impacto positivo na produção final das cadeiras porta-bebés, no que diz respeito à diminuição de filas de espera entre postos, diminuição dos tempos de inatividade e aumento da eficiência da linha. Este modelo proposto pode ser ajustado às restantes linhas de montagem com vista à sua otimização.Balancing a production line aims to eliminate the production “bottleneck”, promoting maximum productivity and efficiency, maintaining the proper work rhythm of the production process. In this way, the present project focuses on the identification and elimination of waste, improving the assembly processes, by studying the cycle times of the workstations and the tasks performed by each operator. In the analysis carried out on the line, the process is described with all the tasks inherent to the assembly of the baby seat, as well as the photographs of the work and control instructions that help the assembly of the chair. Likewise, the data collected initially and the improvement proposal are presented. Thus said, an interface was created with Excel, which indicates the theoretical number of operators needed, given the number of orders required for a certain period of time. This interface uses an optimization problem, which is solved using Solver to allocate the different tasks to the operators. The analysis carried out, if implemented, could have a positive impact on the final production of baby seats, in terms of reducing queues between stations, reducing downtime and increasing the efficiency of the line. This proposed model can be adjusted to the remaining assembly lines with a view to its optimization

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

Optimisation of a water company’s waste pumping asset base with a focus on energy reduction

This thesis was submitted for the award of Doctor of Philosophy and was awarded by Brunel University LondonWater companies use a significant quantity of electricity for the operation of their clean and wastewater assets. Rising energy prices have led to higher energy bills within the water companies, which has increased operating costs. Thus, improvements in demand side energy management are needed to increase efficiency and reduce costs, which forms the premise for this research project. Thames Water Utilities Ltd has identified that improvements in demand side energy management is required and is currently researching various methods to reduce energy consumption. One initiative included the upgrade of a variety of site telemetry assets. By deploying these new telemetry assets, Thames Water Utilities Ltd are more able to liberate the asset data and as such, be able to make informed decisions on how better to control and optimise the target sites, which is where this research project has seen further opportunities. This enhanced telemetry and SCADA infrastructure will enable successful research to further develop an intelligent integrated system that tackles pump scheduling and process control with the emphasis on energy management. The use of modern techniques, such as artificial intelligence, to optimise the network operation is gradually gaining traction. The balance between implementing new technology (with the benefits it may bring) and reluctance to change from the incumbent operating model will always provide challenges in the technology adoption agenda. The main work of this research project included the physical surveying of a wastewater hydraulic catchment, inclusive of all wet well dimensions, lidar overlays, and pump electrical power characteristics. These survey results where then able to be programmed by the research into the company’s' hydraulic model to enable a higher degree of accuracy in the modelling, as well as enabling electrical power as a measurable output. From here, the model was then able to be optimised, focussing on electrical energy as an output variable for reduction. The research concluded that electrical energy consumption over time can be reduced using the aforementioned strategies and as such recommends further work to move from the model environment to physical architecture. It does so with the key message that risk tolerances on water levels must be pre-agreed with hydraulic specialists prior to deployment

Large space structures and systems in the space station era: A bibliography with indexes (supplement 03)

Bibliographies and abstracts are listed for 1221 reports, articles, and other documents introduced into the NASA scientific and technical information system between January 1, 1991 and June 30, 1991. Topics covered include large space structures and systems, space stations, extravehicular activity, thermal environments and control, tethering, spacecraft power supplies, structural concepts and control systems, electronics, advanced materials, propulsion, policies and international cooperation, vibration and dynamic controls, robotics and remote operations, data and communication systems, electric power generation, space commercialization, orbital transfer, and human factors engineering

Space Station Systems: a Bibliography with Indexes (Supplement 8)

This bibliography lists 950 reports, articles, and other documents introduced into the NASA scientific and technical information system between July 1, 1989 and December 31, 1989. Its purpose is to provide helpful information to researchers, designers and managers engaged in Space Station technology development and mission design. Coverage includes documents that define major systems and subsystems related to structures and dynamic control, electronics and power supplies, propulsion, and payload integration. In addition, orbital construction methods, servicing and support requirements, procedures and operations, and missions for the current and future Space Station are included