Optimization of Automotive Manufacturing Layout for Productivity Improvement / Muhamad Magffierah Razali ...[et al.]

This paper deal with an optimization of automotive manufacturing layout by using meta-heuristics approach aided with discrete event simulation (WITNESS Simulation). The objective of this study is to balance the workload, increase line efficiency, and improve productivity by optimizing assembly line balancing (ALB) using Genetic Algorithm. The current assembly line layout operated under the circumstance where idle time is high due to unbalance workload. After the optimization process takes place, the workload distribution in each workstation has shown a significant improvement. Furthermore, productivity improvement was gained after the optimization followed by increment in term of line efficiency by 18%. In addition, the number of workstation needed to assemble the product can be reduced from current layout (17 workstations) to an improved layout (14 workstations). The current study contributes to the implementation of Genetic Algorithm in ALB to improve productivity of related automotive manufacturing industry

Mathematical Modelling of Mixed-Model Assembly Line Balancing Problem with Resources Constraints

Modern manufacturing industries nowadays encounter with the challenges to provide a product variety in their production at a cheaper cost. This situation requires for a system that flexible with cost competent such as Mixed-Model Assembly Line. This paper developed a mathematical model for Mixed-Model Assembly Line Balancing Problem (MMALBP). In addition to the existing works that consider minimize cycle time, workstation and product rate variation, this paper also consider the resources constraint in the problem modelling. Based on the finding, the modelling results achieved by using computational method were in line with the manual calculation for the evaluated objective functions. Hence, it provided an evidence to verify the developed mathematical model for MMALBP. Implications of the results and future research directions were also presented in this paper

A Review of Two-sided Assembly Line Balancing Problem

Assembly line balancing (ALB) is concerned with assigning tasks within an assembly line to meet the required production rate for optimization purposes. On the other hand, two-sided ALB performs double-sided assembly operation on a single assembly line. In this paper, we have focused the survey on two-sided assembly line balancing (2S-ALB) research problems. The numerous factors mentioned in 2SALB literature were actually based on problem resolutions, and this paper will quote any preferred literature considering the frequent citation. In particular, this review explores in detail the ALB problems, optimization methods, objective functions, and specific constraints used in solving 2S-ALB problems. Among the purposes of ALB problems is that it traditionally focuses on simple ALB with various engaging approaches. General ALB comes second because of its complexity and nondeterministic polynomial (NP)-hard-classified problems. However, due to the current manufacturing issues, GALB problems, such as 2S-ALB, are forced to be examined and this comprehensive literature will specify anything necessary for the optimization purposes. Finally, future research direction has been discovered and put forward as the suggestion

Modelling of Two-sided Assembly Line Balancing Problem with Resource Constraints

Two-sided assembly line balancing (2S-ALB) problems is practically useful in improving the production of large-sized high-volume products. Many published papers have proposed various approaches to balance this well-known ALB problem. However, little attention is given in formulating the 2S-ALB problems. In this paper, 2S-ALB is modelled with four different objective functions comprising minimization of workstations, mated- workstation, idle time and resource constraints. In different with existing model, this paper also considers resource constraint with a mathematical modelling formulation in solving the 2S- ALB problems. The modelling procedures are present for each objective functions with a simple 2S-ALB example problem. Then, the anticipated performance solution is obtained from the test problem

Optimization of Automotive Manufacturing Layout for Productivity Improvement

This paper deal with an optimization of automotive manufacturing layout by using meta-heuristics approach aided with discrete event simulation (WITNESS Simulation). The objective of this study is to balance the workload, increase line efficiency, and improve productivity by optimizing assembly line balancing (ALB) using Genetic Algorithm. The current assembly line layout operated under the circumstance where idle time is high due to unbalance workload. After the optimization process takes place, the workload distribution in each workstation has shown a significant improvement. Furthermore, productivity improvement was gained after the optimization followed by increment in term of line efficiency by 18%. In addition, the number of workstation needed to assemble the product can be reduced from current layout (17 workstations) to an improved layout (14 workstations). The current study contributes to the implementation of Genetic Algorithm in ALB to improve productivity of related automotive manufacturing industry

Assembly Line Balancing using Heuristic Approaches in Manufacturing Industry / Muhammad Razif Abdullah Make...[et al.]

Assembly Line Balancing (ALB) plays a vital function especially in the production line. The installation of an assembly line is a long-term decision and requires large capital of investments. It is important that such a system is designed and balanced so that it able to work efficiently as possible. Many previous researches have proposed different heuristic approach in optimizing the assembly line. However little attention is given toward simulation analysis as proved of the proposed method. In this paper, a real industrial data of simple ALB problem is optimized and simulated for minimizing the number of workstation. Three proposed heuristics in order to improve the efficiency of the production are reviewed before a discrete simulation approach is used to compare the optimized performance. The anticipated performance of computational result is obtained from the problem comprising the workstation and labour performance output

Assembly Line Balancing using Heuristic Approaches in Manufacturing Industry

Assembly Line Balancing (ALB) plays a vital function especially in the production line. The installation of an assembly line is a long-term decision and requires large capital of investments. It is important that such a system is designed and balanced so that it able to work efficiently as possible. Many previous researches have proposed different heuristic approach in optimizing the assembly line. However little attention is given toward simulation analysis as proved of the proposed method. In this paper, a real industrial data of simple ALB problem is optimized and simulated for minimizing the number of workstation. Three proposed heuristics in order to improve the efficiency of the production are reviewed before a discrete simulation approach is used to compare the optimized performance. The anticipated performance of computational result is obtained from the problem comprising the workstation and labour performance output

Recent trend in mixed-model assembly line balancing optimization using soft computing approaches

Purpose - This paper aims to review and discuss four aspects of mixed-model assembly line balancing (MMALB) problem mainly on the optimization angle. MMALB is a non-deterministic polynomial-time hard problem which requires an effective algorithm for solution. This problem has attracted a number of research fields: manufacturing, mathematics and computer science. Design/methodology/approach - This paper review 59 published research works on MMALB from indexed journal. The review includes MMALB problem varieties, optimization algorithm, objective function and constraints in the problem. Findings - Based on research trend, this topic is still growing with the highest publication number observed in 2016 and 2017. The review indicated that the future research direction should focus on human factors and sustainable issues in the problem modeling. As the assembly cost becomes crucial, resource utilization in the assembly line should also be considered. Apart from that, the growth of new optimization algorithms is predicted to influence the MMALB optimization, which currently relies on well-established algorithms. Originality/value - The originality of this paper is on the research trend in MMALB. It provides the future direction for the researchers in this field