Balancing and sequencing of mixed model assembly lines. Considering mixed model manual automobile assembly systems, setup times. Assemblyline balancing assemblyline balancing objective is to minimize the imbalance between machines or personnel while meeting required output starts with the precedence relationships determine cycle time calculate theoretical minimum number of workstations balance the line by assigning specific tasks to workstations. However, in todays competitive market, the mixed model assembly line balancing problem has been turned into an operational problem. This project mainly focuses on improving overall efficiency of single model assembly line by reducing the bottleneck activities, cycle time and distribution of work load at each work station by line. Cardinality constrained parallel machine scheduling.
Mixed model assembly introduction mixed model production is the practice of assembling several distinct models of a product on the same assembly line without changeovers and then sequencing those models in a way that smoothes the demand for upstream components. Complexity in mixed model assembly lines mixed model assembly lines have been recognized as a major enabler to handle product variety. By using a developed simulation tool, called as fact model. The assembly line balance alb is known as the classic problem of al balancing, consisting in the allocation of tasks on a workstation in a way that downtime is minimized and the precedence constraints are met rekiek et al. A mathematical programming model of the assembly line balancing problem dennis l. Pdf production planning of mixedmodel assembly lines. Balancing mixedmodel assembly lines in real world complex. Though attempts have been made on the single model as well as the mixed model assembly line balancing problems in the past, a critical analysis is not carried out in terms of balancing loss while using mixed model assembly line balancing in contrast to that of the single model assembly line balancing for a give set of problems. Mixed model line balancing and sequencing was the early approach used for handling increasing product variety. Recent attention to justintime manufacturing brings considerable focus on production of variety of models on the same assembly line, so is the need for mixed. This paper considers the problem of mixed model assembly line balancing. Phd thesis, free university of brussels, cadcam department, brussels, belgium. Usually in a mixed model assembly line, the models being assembled have differences in the set of tasks associated with each model, the.
We can distinguish two approaches in the literature on the mixed model line balancing problem, that both transform this problem into a single model line balancing problem. An example of line balancing assigning tasks to stations a precedence diagram is a lot like a process flow diagram. The solution procedures such as optimum seeking procedures, heuristic, simulation and other approaches have many ways in detail to solve the line balancing problem. A costoriented model for multimanned assembly line. Solving a multi objective mixed model assembly line balancing. Assembly line balancing alb and sequencing is an active area of optimization research in operations management. Balancing and scheduling of flexible mixed model assembly lines. Modeling and solving mixedmodel assembly line balancing. The 2salb is classified under the general assembly line balancing galb problem, besides the simple assembly line balancing salb problem. Assembly line balancing alb is an attractive means for optimal balancing of the assembly linesflow lines in mass production and continuous repetitive production systems largescale serial. Mixed model assembly line the use of mixed model assembly lines in a changing environment requires methods for efficient design and redesign of the assembly system in which they are used. Balancing mixedmodel assembly lines with simulation.
Mixed model line balancing and scheduling assembly line. Mixed model assembly line literature involves two problems. Modeling of manufacturing complexity in mixedmodel assembly. First, the balance problem is formulated, and some of the difficulties of achieving effective balances in practice are noted. Assembly line design multiple objective grouping genetic algorithm and the balancing of mixedmodel hybrid assembly line. A focus on model formulation 6412 line balancing problem mmabp by considering the three objective functions based on demand ratio. Mixed model alb is categorized under general assembly line balancing which produce several models having similar characteristics on a single assembly line 4. Thomopoulos 1967 was the first to use the combined precedence diagram to solve mixed model assembly line balancing problem malbp. Line balancing techniques to improve productivity using. Assembly line design multiple objective grouping genetic algorithm and the balancing of mixed model hybrid assembly line. Line balancing is the problem of assigning operation to workstation along an assembly line, in such a way that assignment is optimal in some sense. Heuristic methods for the mixedmodel assembly line.
On mixed model assembly line, there is more than one precedence diagram for different models. In order to optimize mixedmodel assembly line concept of parallel sub assembly shop had been used. Thus, in figure 4, there are two yellows for every green and two yellows for every red. Pdf on aug 14, 2019, k dziki and others published mixed model assembly line balancing problem with tasks assignment find, read and cite all the research you need on researchgate. With mixed model assembly, figure 4, multiple models are interspersed on the same assembly line. Mixed model assembly line balancing problem with fuzzy operation times and drifting operations weida xu tianyuan xiao dept. Mixed model assembly line design in a maketoorder environment.
Apr 12, 2017 mixed model assembly lines are increasingly used by manufacturers to meet the diversified needs of their customers and reduce the costs associated with large product inventories. Mixed model assembly line balancing free download as pdf file. The general tendency in current studies is to deal with these problems in different time frames. Assembly line balancing is used for which type of production. Introduction the twosided assembly line is a line where tasks on the same product item can be performed in parallel at both sides of the line. A mathematical programming model of the assembly line. Balancing mixedmodel assembly line to reduce work overload in a. This article proposes a heuristic that aims to balance production lines subjected to several product models in order to attenuate capacity restrictions in workstations. Mixed model assembly line balancing mathematical optimization. Mar 26, 2014 mixed models line balancing bhoomiboon ph.
Production is initiated with a job which is a workpiece that is launched down the line. The processes used to accomplish the assembly of the components can be divided into three major categories. Optimize assembly production line using line balancing. This paper describes a procedure of adapting single model line balancing techniques to mixed model. Mixed assembly line balancing method in scenarios with. Mixed model assembly lines are increasingly used by manufacturers to meet the diversified needs of their customers and reduce the costs associated with large product inventories. This paper discusses the issue of mixedmodel line balancing of complex workstations using real data from some automotive assembly lines.
Pdf recent trend in mixedmodel assembly line balancing. The amount of work required to assemble units can vary from model to model, creating an uneven flow of work along the line. Mixed model assembly occurs when more than one model of the same general product are intermixed on one assembly line. Pdf mixed model assembly line balancing problem under. An analytical approach for single and mixedmodel assembly. Mixedmodel assembly is key to profitability 20160505. Solving a multiobjective mixedmodel assembly line balancing. Mathematical modelling of mixedmodel assembly line balancing. These formulations are the basis for a model in goal programming form. The concept of an assembly line al came to the fact when the finished product is inclined to the perception of product modularity. The balancing problem deals with the assignment of tasks to work stations. Assembly systems and line balancing discrete products are assembled from components. Combined precedence is to be formed by using the individual items precedence diagrams.
Modelling of twosided assembly line balancing problem with. Multimodel production and assembly line balancing caravans. New formulations for the assembly line balance problem are proposed based on interviews and surveys of practicing engineers. In this paper, we propose mixed integer programming mip and constraint. Comparison of single model and multimodel assembly line.
This paper is the first one of the two papers entitled modeling and solving mixed model assembly line balancing problem with setups, which has the aim of developing the mathematical programming formulation of the problem and solving it with a hybrid metaheuristic approach. Heuristic methods for the mixedmodel assembly line balancing. Mixedmodel twosided assembly line balancing using a. Using mixed model assembly line balancing problem, are proved to be useful in identifying and solving line problems. Real of simply assembly line balancing using factmodel.
May 05, 2016 the term mixed model generally refers to a manufacturing environment where there is a high degree of variation, such as hundreds or thousands of different options and combinations, including customerspecified components, and multiple product types being built on the same assembly line. Bricker shuwhwey juang department of industrial engineering the university of iowa working paper november 1993 abstract. China abstract assembly line balancing problem albp means assigning a series of task elements to uniform sequential stations under certain restrictions. A costoriented model for multimanned assembly line balancing problem abolfazl kazemia, abdolhossein sedighib a assistant professor, faculty of industrial and mechanical engineering, qazvin branch, islamic azad university, qazvin, iran. The remaining sections of this paper are organized as follow. A coevolutionary algorithm for balancing and sequencing in mixed model assembly lines.
Whenever the demand structure shifts to another modelmix, the line balance might need. Pdf mixedmodel assembly line balancing problem with. The objectives are 1 cycle time minimization, 2 workload variation minimization and 3 total cost minimization. Assembly line balancing assembly line balancing objective is to minimize the imbalance between machines or personnel while meeting required output starts with the precedence relationships determine cycle time calculate theoretical minimum number of workstations balance the line by assigning specific tasks to workstations.
It provides shorter line length, reduced throughput time, lower cost of tools and fixtures, and less material handling kim et al. Scholl, 2006 was the first to give an analytical statement of assembly line balancing problems. Compared with the single model line little attention has been paid to the mixed and the multi model line balancing problem. This assembly system design is focused on issues of assembly system or line configuration, balancing, and equipment selection. The ratio of each model to total output is consistent with customer demand. This paper is the first one of the two papers entitled modeling and solving mixedmodel assembly line balancing problem with setups, which has the aim of developing the mathematical programming formulation of the problem and solving it with a hybrid metaheuristic approach. Assembly lines are flow line production systems which are of great importance in the industrial production of high quantity standardized commodities and more recently even gained importance in low volume production of customized products. However, the assembly process becomes very complex when the number of product variants is high, which, in turn, may impact the system performance in terms of quality and productivity. Mixed model assembly line balancing problem under uncertainty.
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