Integrating ant colony and genetic algorithms in the balancing and scheduling of complex assembly lines

Copyright © 2015 Springer. This is a PDF file of an unedited manuscript that has been accepted for publication in The International Journal of Advanced Manufacturing Technology. The final publication is available at: http://link.springer.com/article/10.1007/s00170-015-7320-y. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.Different from a large number of existing studies in the literature, this paper addresses two important issues in managing production lines, the problems of line balancing and model sequencing, concurrently. A novel hybrid agent-based ant colony optimization–genetic algorithm approach is developed for the solution of mixed model parallel two-sided assembly line balancing and sequencing problem. The existing agent-based ant colony optimization algorithm is enhanced with the integration of a new genetic algorithm-based model sequencing mechanism. The algorithm provides ants the opportunity of selecting a random behavior among ten heuristics commonly used in the line balancing domain. A numerical example is given to illustrate the solution building procedure of the algorithm and the evolution of the chromosomes. The performance of the developed algorithm is also assessed through test problems and analysis of their solutions through a statistical test, namely paired sample t test. In accordance with the test results, it is statistically proven that the integrated genetic algorithm-based model sequencing engine helps agent-based ant colony optimization algorithm robustly find significantly better quality solutions

Reducing physical ergonomic risks at assembly lines by line balancing and job rotation: A survey

Factors such as repetitiveness of work, required application of forces, handling of heavy loads, and awkward, static postures expose assembly line workers to risks of musculoskeletal disorders. As a rule, companies perform a post hoc analysis of ergonomic risks and examine ways to modify workplaces with high ergonomic risks. However, it is possible to lower ergonomic risks by taking ergonomics aspects into account right from the planning stage. In this survey, we provide an overview of the existing optimization approaches to assembly line balancing and job rotation scheduling that consider physical ergonomic risks. We summarize major findings to provide helpful insights for practitioners and identify research directions

Modelling and Solving Mixed-model Parallel Two-sided Assembly Line Problems

The global competitive environment and the growing demand for personalised products have increased the interest of companies in producing similar product models on the same assembly line. Companies are forced to make significant structural changes to rapidly respond to diversified demands and convert their existing single-model lines into mixed-model lines in order to avoid unnecessary new line construction cost for each new product model. Mixed-model assembly lines play a key role in increasing productivity without compromising quality for manufacturing enterprises. The literature is extensive on assembling small-sized products in an intermixed sequence and assembling large-sized products in large volumes on single-model lines. However, a mixed-model parallel two-sided line system, where two or more similar products or similar models of a large-sized product are assembled on each of the parallel two-sided lines in an intermixed sequence, has not been of interest to academia so far. Moreover, taking model sequencing problem into consideration on a mixed-model parallel two-sided line system is a novel research topic in this domain. Within this context, the problem of simultaneous balancing and sequencing of mixed-model parallel two-sided lines is defined and described using illustrative examples for the first time in the literature. The mathematical model of the problem is also developed to exhibit the main characteristics of the problem and to explore the logic underlying the algorithms developed. The benefits of utilising multi-line stations between two adjacent lines are discussed and numerical examples are provided. An agent-based ant colony optimisation algorithm (called ABACO) is developed to obtain a generic solution that conforms to any model sequence and it is enhanced step-by-step to increase the quality of the solutions obtained. Then, the algorithm is modified with the integration of a model sequencing procedure (where the modified version is called ABACO/S) to balance lines by tracking the product model changes on each workstation in a complex production environment where each of the parallel lines may a have different cycle time. Finally, a genetic algorithm based model sequencing mechanism is integrated to the algorithm to increase the robustness of the obtained solutions. Computational tests are performed using test cases to observe the performances of the developed algorithms. Statistical tests are conducted through obtained results and test results establish that balancing mixed-model parallel two-sided lines together has a significant effect on the sought performance measures (a weighted summation of line length and the number of workstations) in comparison with balancing those lines separately. Another important finding of the research is that considering model sequencing problem along with the line balancing problem helps algorithm find better line balances with better performance measures. The results also indicate that the developed ABACO and ABACO/S algorithms outperform other test heuristics commonly used in the literature in solving various line balancing problems; and integrating a genetic algorithm based model sequencing mechanism into ABACO/S helps the algorithm find better solutions with less amount of computational effort

Best matching processes in distributed systems

The growing complexity and dynamic behavior of modern manufacturing and service industries along with competitive and globalized markets have gradually transformed traditional centralized systems into distributed networks of e- (electronic) Systems. Emerging examples include e-Factories, virtual enterprises, smart farms, automated warehouses, and intelligent transportation systems. These (and similar) distributed systems, regardless of context and application, have a property in common: They all involve certain types of interactions (collaborative, competitive, or both) among their distributed individuals—from clusters of passive sensors and machines to complex networks of computers, intelligent robots, humans, and enterprises. Having this common property, such systems may encounter common challenges in terms of suboptimal interactions and thus poor performance, caused by potential mismatch between individuals. For example, mismatched subassembly parts, vehicles—routes, suppliers—retailers, employees—departments, and products—automated guided vehicles—storage locations may lead to low-quality products, congested roads, unstable supply networks, conflicts, and low service level, respectively. This research refers to this problem as best matching, and investigates it as a major design principle of CCT, the Collaborative Control Theory. The original contribution of this research is to elaborate on the fundamentals of best matching in distributed and collaborative systems, by providing general frameworks for (1) Systematic analysis, inclusive taxonomy, analogical and structural comparison between different matching processes; (2) Specification and formulation of problems, and development of algorithms and protocols for best matching; (3) Validation of the models, algorithms, and protocols through extensive numerical experiments and case studies. The first goal is addressed by investigating matching problems in distributed production, manufacturing, supply, and service systems based on a recently developed reference model, the PRISM Taxonomy of Best Matching. Following the second goal, the identified problems are then formulated as mixed-integer programs. Due to the computational complexity of matching problems, various optimization algorithms are developed for solving different problem instances, including modified genetic algorithms, tabu search, and neighbourhood search heuristics. The dynamic and collaborative/competitive behaviors of matching processes in distributed settings are also formulated and examined through various collaboration, best matching, and task administration protocols. In line with the third goal, four case studies are conducted on various manufacturing, supply, and service systems to highlight the impact of best matching on their operational performance, including service level, utilization, stability, and cost-effectiveness, and validate the computational merits of the developed solution methodologies

Hybrid ant colony system algorithm for static and dynamic job scheduling in grid computing

Grid computing is a distributed system with heterogeneous infrastructures. Resource management system (RMS) is one of the most important components which has great influence on the grid computing performance. The main part of RMS is the scheduler algorithm which has the responsibility to map submitted tasks to available resources. The complexity of scheduling problem is considered as a nondeterministic polynomial complete (NP-complete) problem and therefore, an intelligent algorithm is required to achieve better scheduling solution. One of the prominent intelligent algorithms is ant colony system (ACS) which is implemented widely to solve various types of scheduling problems. However, ACS suffers from stagnation problem in medium and large size grid computing system. ACS is based on exploitation and exploration mechanisms where the exploitation is sufficient but the exploration has a deficiency. The exploration in ACS is based on a random approach without any strategy. This study proposed four hybrid algorithms between ACS, Genetic Algorithm (GA), and Tabu Search (TS) algorithms to enhance the ACS performance. The algorithms are ACS(GA), ACS+GA, ACS(TS), and ACS+TS. These proposed hybrid algorithms will enhance ACS in terms of exploration mechanism and solution refinement by implementing low and high levels hybridization of ACS, GA, and TS algorithms. The proposed algorithms were evaluated against twelve metaheuristic algorithms in static (expected time to compute model) and dynamic (distribution pattern) grid computing environments. A simulator called ExSim was developed to mimic the static and dynamic nature of the grid computing. Experimental results show that the proposed algorithms outperform ACS in terms of best makespan values. Performance of ACS(GA), ACS+GA, ACS(TS), and ACS+TS are better than ACS by 0.35%, 2.03%, 4.65% and 6.99% respectively for static environment. For dynamic environment, performance of ACS(GA), ACS+GA, ACS+TS, and ACS(TS) are better than ACS by 0.01%, 0.56%, 1.16%, and 1.26% respectively. The proposed algorithms can be used to schedule tasks in grid computing with better performance in terms of makespan

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

Combining non-dominance, objective-order and spread metric to extend firefly algorithm to multi-objective optimization

In this paper, we propose an extension of the firefly algorithm (FA) to multi-objective optimization. FA is a swarm intelligence optimization algorithm inspired by the flashing behavior of fireflies at night that is capable of computing global solutions to continuous optimization problems. Our proposal relies on a fitness assignment scheme that gives lower fitness values to the positions of fireflies that correspond to non-dominated points with smaller aggregation of objective function distances to the minimum values. Furthermore, FA randomness is based on the spread metric to reduce the gaps between consecutive non-dominated solutions. The obtained results from the preliminary computational experiments show that our proposal gives a dense and well distributed approximated Pareto front with a large number of points.. The authors thank the anonymous referees for the valuable suggestions. This work has been supported by FCT (Funda¸c˜ao para a Ciˆencia e Tecnologia, Portugal) in the scope of the projects: PEst-OE/MAT/UI0013/2014 and PEstOE/EEI/UI0319/2014

Balanceamento de linhas de montagem: novas perspectidas e procedimentos

Doutoramento em Gestão IndustrialNo presente trabalho é apresentado um conjunto de procedimentos para o balanceamento de linhas de montagem de modelo-misto. Linhas de modelo-misto eficientes representam um factor chave de competitividade no actual ambiente de mercado, em que a crescente procura de produtos personalizados requer uma resposta flexível dos sistemas de produção. Os procedimentos propostos, baseados nas meta-heurísticas ‘simulated annealing’, ‘algoritmos genéticos’ e ‘optimização por colónias de formigas’, são capazes de abordar algumas características do processo de montagem presentes nas linhas reais (e.g., utilização de postos paralelos, restrições de zona, linhas de dois lados, linhas em forma de U) que a maioria das técnicas existentes na literatura não considera. Isto constitui uma contribuição relevante quer para o conhecimento científico quer para o conhecimento industrial na área do balanceamento de linhas de montagem. Alguns dos procedimentos foram utilizados no balanceamento de linhas de montagem reais com o objectivo de testar a sua flexibilidade de adaptação às condições de operação em ambientes industriais.In this work a set of procedures to efficiently balance mixed-model assembly lines is proposed. Efficient mixed-model lines represent a key factor of competitiveness in the actual market environment, in which the growing demand for customised products increases the pressure for manufacturing flexibility. The proposed procedures, based on the meta heuristics ‘simulated annealing’, ‘genetic algorithms’ and ‘ant colony optimisation’, are able to address some particular features of the assembly process very common in real mixed model assembly lines (e.g., use of parallel workstations, zoning constraints, task side constraints, U-shaped layouts) that most of the techniques existing in the literature do not consider. This is a major contribution to the scientific and industrial knowledge on the line balancing subject. Some of the procedures were applied to real assembly lines in order to test their flexibility to cope with real industrial settings, as they may differ significantly from theoretical problems