Improving the resolution of the simple assembly line balancing problem type E

The simple assembly line balancing problem type E (abbreviated as SALBP-E) occurs when the number of workstations and the cycle time are variables and the objective is to maximise the line efficiency. In contrast with other types of SALBPs, SALBP-E has received little attention in the literature. In order to solve optimally SALBP-E, we propose a mixed integer liner programming model and an iterative procedure. Since SALBP-E is NP-hard, we also propose heuristics derived from the aforementioned procedures for solving larger instances. An extensive experimentation is carried out and its results show the improvement of the SALBP-E resolution

A mathematical model and artificial bee colony algorithm for the lexicographic bottleneck mixed-model assembly line balancing problem

This is the author accepted manuscript. The final version is available from the publisher via the DOI in this record.Typically, the total number of required workstations are minimised for a given cycle time (this problem is referred to as type-1), or cycle time is minimised for a given number of workstations (this problem is referred to as type-2) in traditional balancing of assembly lines. However, variation in workload distributions of workstations is an important indicator of the quality of the obtained line balance. This needs to be taken into account to improve the reliability of an assembly line against unforeseeable circumstances, such as breakdowns or other failures. For this aim, a new problem, called lexicographic bottleneck mixed-model assembly line balancing problem (LB-MALBP), is presented and formalised. The lexicographic bottleneck objective, which was recently proposed for the simple single-model assembly line system in the literature, is considered for a mixed-model assembly line system. The mathematical model of the LB-MALBP is developed for the first time in the literature and coded in GAMS solver, and optimal solutions are presented for some small scale test problems available in the literature. As it is not possible to get optimal solutions for the large-scale instances, an artificial bee colony algorithm is also implemented for the solution of the LB-MALBP. The solution procedures of the algorithm are explored illustratively. The performance of the algorithm is also assessed using derived well-known test problems in this domain and promising results are observed in reasonable CPU times

Optimization of two sided assembly line balancing with resource constraint

Two-sided assembly line balancing (2S-ALB) problems are practically useful in improving the production of large-sized high-volume products. Many research has proposed various approaches to study and balance this well-known ALB problem. Although much attention has been given to solve and optimize 2S-ALB, the majority of the research assumed the workstation has similar capabilities. This research has been conducted in an automotive assembly line, where most of the equipment used in assembly is different from one workstation to another. The assumption that all workstation has similar capabilities lead to inefficient resource utilization in assembly line design. This research aims to model and optimize 2S-ALB with resource constraints. Besides optimizing the line balancing, the proposed model also will minimize the number of resources in the two-sided assembly line. The research begins with problem formulation by establishing four optimization objectives. The considered optimization objectives were to minimize the number of workstations, number of mated-workstation, total idle time, and number of resources. For optimization purpose, Particle Swarm Optimization is modified to find the best solution besides reducing the dependencies on a single best solution. This is conducted by replacing the best solution with the top three solutions in the reproduction process. A set of benchmark problems for 2S-ALB were used to test the proposed Modified Particle Swarm Optimization (MPSO) in the computational experiment. Later, the proposed 2S-ALB with resource constraint model and algorithm was validated using a case study problem. The computational experiment result using benchmark test problems indicated that the proposed MPSO was able to search for better solution in 91.6% of the benchmark problems. The good performance of MPSO is attributed to its ability to maintain particle diversity over the iteration. Meanwhile, the case study result indicated that the proposed 2S-ALB with resource constraint model and MPSO algorithm are able to be utilized for the real problem. In the future, the multiobjective optimization problem will be considered to be optimized for other types of general assembly lines

An Improved Ant Colony Optimisation Algorithm for Type-I Parallel Two-Sided Assembly Line Balancing Problem

Publishedn/aThe first author wishes to thank the Balikesir University and University of Exeter for their financial supports

A mixed-integer programming model for cycle time minimization in assembly line balancing: Using rework stations for performing parallel tasks

[EN] In assembly lines, rework stations are generally used for reprocessing defective items. On the other hand, using rework stations for this purpose only might cause inefficient usage of the resources in this station especially in an assembly line with a low defective rate. In this study, a mixed-integer programming model for cycle time minimization is proposed by considering the use of rework stations for performing parallel tasks. By linearizing the non-linear constraint about parallel tasks using a variate transformation, the model is transformed to a linear-mixed-integer form. In addition to different defective rates, different rework station positions are also considered using the proposed model. The performance of the model is analyzed on several test problems from the related literature.Cavdur, F.; Kaymaz, E. (2020). A mixed-integer programming model for cycle time minimization in assembly line balancing: Using rework stations for performing parallel tasks. 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New matrix methodology for algorithmic transparency in assembly line balancing using a genetic algorithm

© 2022. This manuscript version is made available under the CC-BY-NC-ND 4.0 license https://creativecommons.org/licenses/by-nc-nd/4.0/This article focuses on the Mixed-Model Assembly Line Balancing single-target problem of type 2 with single-sided linear assembly line configurations, which is common in the industrial environment of small and medium-sized enterprises (SMEs). The main objective is to achieve Algorithmic Transparency (AT) when using Genetic Algorithms for the resolution of balancing operation times. This is done by means of a new matrix methodology that requires working with product functionalities instead of product references. The achieved AT makes it easier for process engineers to interpret the obtained solutions using Genetic Algorithms and the factors that influence decisions made by algorithms, thereby helping in the later decision-making process. Additionally, through the proposed new matrix methodology, the computational cost is reduced with respect to the stand-alone use of Genetic Algorithms. The AT produced using the new matrix methodology is validated through its application in an industry-based paradigmatic example.Peer ReviewedPostprint (published version

AUTOMATIZACIÓN DE UN SISTEMA DIDÁCTICO PARA ESTUDIOS DE TIEMPOS Y MOVIMIENTOS

En este artículo se describe la implementación de un sistema de automatización de dos bandas transportadoras empleadas como apoyo didáctico para el estudio de tiempos y movimientos en la UAM-Azcapotzalco. El sistema está basado en un Controlador Lógico Programable (PLC) con pantalla integrada, el cual permite la operación de las bandas bajo tres modos de funcionamiento. El modo de operación, así como los parámetros asociados al experimento, es especificado por el usuario mediante diversos menús de opciones disponibles en la pantalla del controlador. Adicionalmente, el sistema despliega en la pantalla del controlador información de las principales variables asociadas al ejercicio como son: tiempos de ciclo, tiempos por estación, número de piezas elaboradas, etc. En paralelo al monitoreo en tiempo real de las variables, el sistema genera un archivo en Microsoft Excel para el posterior análisis de los datos. El sistema desarrollado amplió las capacidades de experimentación de los equipos existentes, hizo más eficiente su uso e incrementó la confiabilidad de los resultados que se obtienen

SISTEMA DE MONITOREO PARA UN EQUIPO DE ESTUDIOS DE TIEMPOS Y MOVIMIENTOS

ResumenLos laboratorios de Ingeniería Industrial de la UAM-Azcapotzalco cuentan con equipos que sirven como apoyo para la enseñanza de asignaturas relacionadas con el estudio y mejoramiento de la productividad de procesos industriales. En este artículo se describe el diseño y construcción de un sistema que permite desplegar en una pantalla información asociada al desarrollo de experimentos relacionados con el estudio de tiempos y movimientos. El prototipo construido obtiene información del equipo encargado de controlar la secuencia de operación del sistema didáctico. A partir de estos datos se despliegan diversas pantallas que permiten a los operadores conocer información de las principales variables asociadas al ejercicio como son: modo de operación, tiempos de ciclo, tiempos por estación, número de piezas elaboradas, etc. El sistema basa su funcionamiento en una computadora embebida Raspberry, el intercambio de información entre ésta y el Controlador Lógico Programable del equipo didáctico se realiza mediante el protocolo Modbus. Pruebas realizadas han demostrado una operación correcta del prototipo, mismo que se empezará a utilizar en el siguiente período lectivo.Palabras Claves: Controladores Lógicos Programables, Modbus IP, Monitoreo de la Producción, Raspberry, Sistema Andon. MONITORING SYSTEM FOR AN EQUIPMENT OF STUDY OF TIMES AND MOVEMENTSAbstractThe Industrial Engineering Laboratories of the UAM-Azcapotzalco have equipment that serves as support for the teaching of subjects related to the study and improvement of the productivity of industrial processes. This article describes the construction of a system to display on screen, information associated with the development of experiments related to time and motion studies. This prototype obtains information from the controller in charge of the sequence of operation of the teaching system. Based on these data, several screens are displayed that allow operators to know information about the main variables associated with the exercise such as: operation mode, cycle time, time per work station, number of elaborated pieces, etc. The system bases its operation on a Raspberry embedded computer, the exchange of information between it and the Programmable Logic Controller of the teaching equipment is done through the Modbus protocol. Tests carried out have shown a correct operation of the prototype, which will begin to be used in the next school period.Keywords: Andon System, Modbus IP, Production Monitoring, Programmable Logic Controller, Raspberry

IMPACT OF VISUAL INFORMATION SYSTEM IN AN ASSEMBLY PROCESS

En muchos procesos industriales en los cuales el ensamblado de piezas está involucrado, los operadores no cuentan con información en tiempo real del ritmo de producción que llevan. En este artículo se estudia el efecto sobre el rendimiento de los operadores cuando éstos cuentan con información sobre el cumplimiento de los objetivos que les fueron encomendados, para esto, se realizaron dos casos de estudio; en primer lugar, se ensambló una chapa metálica y posteriormente, un soporte para soldar. En ambos casos, se realizó el experimento primero sin ningún tipo de información y posteriormente se incorporó un Sistema Visual de Información. Se efectuó un análisis cuantitativo sobre el efecto que se tuvo en los indicadores claves del proceso al contar con información y sin ella. Adicionalmente, se realizó un análisis cualitativo sobre la percepción que los usuarios tuvieron del sistema de información visual. Los resultados demuestran que, el sistema contribuyó a mejorar la calidad de las piezas ensambladas y a disminuir el tiempo ocioso, al permitir detectar anormalidades dentro del proceso. Por otro lado, los operadores valoraron favorablemente el sistema ya que, determinaron que el nivel de estrés y atención disminuyó, cuando se contaba con información en tiempo real.In many industrial processes in which the assembly of parts is involved, operators do not have real-time information on the rate of production they are carrying. This article studies the effect on the performance of the operators when they have information on the fulfillment of the objectives that were entrusted, for this, two case studies were carried out; First, a metal sheetwas assembled and later, support for welding. In both cases, the experiment was carried out first without any type of information and later a Visual Information System was incorporated. A quantitative analysis was carried out on the effect that was produced in the key indicators of the process when having information and without it. In addition, a qualitative analysis was carried out on the perception that users had of the visual information system. The results show that the system contributes to improving the quality of the assembled parts and reducing idle time, by allowing the detection of abnormalities within the process. On the other hand, the operators valued the system favorably since they determined that the level of stress andattention decreased when there was information in real time

Fitness landscape analysis of the simple assembly line balancing problem type 1

As the simple assembly line balancing problem type 1 (SALBP1) has been proven to be NP-hard, heuristic and metaheuristic approaches are widely used for solving middle to large instances. Nevertheless, the characteristics (fitness landscape) of the problem’s search space have not been studied so far and no rigorous justification for implementing various metaheuristic methods has been presented. Aiming to fill this gap in the literature, this study presents the first comprehensive and in-depth Fitness Landscape Analysis (FLA) study for SALBP1. The FLA was performed by generating a population of 1000 random solutions and improving them to local optimal solution, and then measuring various statistical indices such as average distance, gap, entropy, amplitude, length of the walk, autocorrelation, and fitness-distance among all solutions, to understand the complexity, structure, and topology of the solution space. We solved 83 benchmark problems with various cycle times taken from Scholl’s dataset which required 83000 local searches from initial to optimal solutions. The analysis showed that locally optimal assembly line balances in SALBP1 are distributed nearly uniformly in the landscape of the problem, and the small average difference between the amplitudes of the initial and optimal solutions implies that the landscape was almost plain. In addition, the large average gap between local and global solutions showed that global optimum solutions in SALBP1 are difficult to find, but the problem can be effectively solved using a single-solution-based metaheuristic to near-optimality. In addition to the FLA, a new mathematical formulation for the entropy (diversity) of solutions in the search space for SALBP1 is also presented in this paper