Abstract
This study aims to modify the 5th lean assembly line in order to include a new product model in a combi boiler producer company. After reviewing customers’ needs, company decides to produce a new product. New product model will be produced in the one of the existing lines in the plant. Most suitable line determined according to other product models job sequences’ similarity with new product models’. After the analysis of the production process, the changes and possible constraints for the 5th assembly line are determined. After that, solution procedures are developed, the required calculations are made and implemented. The solutions are developed by various techniques and approaches such as Bubble diagram, Value Stream Mapping, Lean Production, Line Balancing. Particularly, mathematical model, which is solved by IBM ILOG Optimization Studio programmed comprehensive analysis with a simulation model, which is conducted by Arena Simulation software, are presented in this study. The outcomes of the solutions are simulated, compared and automatized. At the end, three options are provided for the 5th lean line to include a new product type while continuing the production process with the current products.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
van Zante-de Fokkert, J.I., de Kok, T.G.: The mixed and multi model line balancing problem: a comparison. Eur. J. Oper. Res. 100(3), 399–412 (1997)
Karabatı, S., Sayın, S.: Assembly line balancing in a mixed-model sequencing environment with synchronous transfers. KocUniversity, Istanbul (2003)
McMullen, P.R., Tarasewich P.: Multi-objective assembly line balancing via a modified ant colony optimization technique 44(1), 27-42 (2007). https://doi.org/10.1080/00207540500216748
Hwang, R., Katayama, H.: A multi-decision genetic approach for workload balancing of mixed-model U-shaped assembly line systems 47(14), 3797–3822 (2007). https://doi.org/10.1080/00207540701851772
Boysen, N., Fliedner, M., Scholl, A.: Assembly line balancing: which model to use when? Universitat Hamburg, Germany (2007)
Widyadana, G.A.: Multi Objective Model for Balancing U-Type Assembly Line with Permanent and Temporary Workers. Petra Christian University, Indonesia (2009)
Fattahi, P., Roshani, A., Roshani, A.: A mathematical model and ant colony algorithm for multi-manned assembly line balancing problem 53, 363–378 (2010). https://doi.org/10.1007/s00170-010-2832-y
Yagmahan, B.: Mixed-model assembly line balancing using a multi-objective ant colony optimization approach. Uludag University, Bursa (2011)
Yoosefelahi, A., Aminnayeri, M., Mosadegh, H., Ardakani, H.D.: Type II robotic assembly line balancing problem: an evolution strategies algorithm for a multi-objective model. Amirkabir University of Technology, Iran (2012)
Al-zubaidy, S.S., AbdAlrazaq, F.F.: Multi-model Production and Assembly Line Balancing (Caravans Production Workshop). Master’s thesis. Journals of University of Babylon, Iraq (2013)
Zeltzer, L., Limère, V., Aghezzaf, E.-H., VanLandeghem, H.: Balancing mixed-model assembly lines in real world complex workstations. Ghent University, Belgium (2013)
Akpinar, Ş., Baykasoglu, A.: Modeling and solving mixed-model assembly line balancing problem with setups. Part I: a mixed integer linear programming model. Dokuz Eylul University, Izmir (2014)
Ramezanian, R., Ezzatpanah, A.: Modeling and solving multi-objective mixed-model assembly line balancing and worker assignment problem. K.N. Toosi University of Technology, Iran (2014)
Manavizadeh, N., Rabbani, M., Radmehr, F.: A new multi-objective approach in order to balancing and sequencing U-shaped mixed model assembly line problem: a proposed heuristic algorithm 79, 415–425 (2015). https://doi.org/10.1007/s00170-015-6841-8
Raj, A.V., Mathew, J., Jose, P. and Sivan, G.: Optimization of Cycle Time in an Assembly Line Balancing Problem. St. Joseph’s College of Engineering and Technology, Palai, India (2016)
Tiacci, L.: Mixed-model U-shaped assembly lines: balancing and comparing with straight lines with buffers and parallel workstations. Università degli Studi di Perugia, Italy (2017)
Christensen, M.K., Janardhanan, M.N., Nielsen, P.: Heuristics for solving a multi-model robotic assembly line balancing problem 5(1), 410–424 (2017). https://doi.org/10.1080/21693277.2017.1403977
Sivasankaran, P., Shahabudeen, P.: Comparison of Single Model and Multi-Model Assembly Line Balancing Solutions. Anna University, India (2017)
Özcan, U., Peker, A.: Karışık Modelli U-Tipi Montaj Hatlarında Hat Dengeleme ve Model Sıralama Problemleri İçin Yeni Bir Sezgisel Yaklaşım. Gazi Üniversitesi Mühendislik-Mimarlık Fakültesi Dergisi 22(2) (2007)
Kılınçcı, Ö.: A petri net approach for solving simple assembly line balancing problem. Dokuz Eylül Üniversitesi Mühendislik Fakültesi Fen ve Mühendislik Dergisi 6(2), 1–15 (2004)
Acknowledgment
This study is supported by TUBITAK (The Scientific and Technological Research Council of Turkey) in the program of “2209-B Undergraduate Research Projects for Industrial Applications Fellowship Program”. We would like to thank our colleagues Cemal Berke Ersoy and Caner Samancı for their help and contribution to the study.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Appendix
Appendix
Rights and permissions
Copyright information
© 2020 Springer Nature Switzerland AG
About this paper
Cite this paper
Telli, D. et al. (2020). The Modification and the Line Balancing of an Assembly Line for the Inclusion of a New Product Model. In: Durakbasa, N., Gençyılmaz, M. (eds) Proceedings of the International Symposium for Production Research 2019. ISPR ISPR 2019 2019. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-31343-2_68
Download citation
DOI: https://doi.org/10.1007/978-3-030-31343-2_68
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-31342-5
Online ISBN: 978-3-030-31343-2
eBook Packages: EngineeringEngineering (R0)