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Sequencing mixed-model flexible assembly lines with variable launching intervals

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Abstract

To solve the sequencing problem in mixed-model flexible assembly lines (MMFALs) with variable launching intervals, a mathematical model aiming to minimize the cost of utility and idle times is developed. To obtain high-quality sequences, an advanced scatter search (ASS) algorithm is proposed. A heuristic approach, i.e. launching intervals between products algorithm (LIBPA), is incorporated into the ASS algorithm to solve the launching interval problem for each sequence. Numerical experiments with different scales are conducted to compare the performance of ASS with genetic algorithm (GA). In addition, we compare the cost of variable launching intervals approach with fixed launching intervals approach. The results indicate that the ASS is efficient and effective, and considering variable launching intervals in mixed-model assembly lines (MMALs) sequencing problem can improve the performance of the line.

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Abbreviations

a i+1 :

Launching interval between product i and i + 1 in a sequence

C Idl :

Unit cost of idle

C U :

Unit cost of utility

d m :

Minimum part-set demand for model m

i :

Indices for products, i = 1, 2, …, I

I :

Total number of products to be sequenced

j :

Indices for stations, j = 1, 2, …, J

J :

Number of stations

L j :

Length of station j

L MD j :

Maximum length that is allowed to exceed the downstream boundary of station j

L MU j :

Maximum length that is allowed to exceed the upstream boundary of station j

L IDF :

Distance associated with first type of idle time

L IDS :

Distance associated with second type of idle time

L UW :

Distance associated with utility work

m :

Indices for models, m = 1, 2, …,M

M :

Number of models

P :

A large set of diverse solutions

R j :

Zero reference point of station j

t mj :

Assembly time for model m at station j

t ID ij :

Total idle time at station j for product i

t w ij :

Utility worker time on product i at station j

v c :

Downstream speed of the conveyor

x im :

1 if product i in a sequence is model m, 0 otherwise

Z f ij :

Finishing position of the work on product i in a sequence at station j

Z s ij :

Starting position of the work on product i in a sequence at station j

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Authors and Affiliations

  1. School of Mechanical Engineering, Tongji University, Shanghai, 201804, China

    Ke-na Tong  (童科娜), Ke-lin Xu  (徐克林) & Yong-qian Zheng  (郑永前)

Authors
  1. Ke-na Tong  (童科娜)
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  2. Ke-lin Xu  (徐克林)
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  3. Yong-qian Zheng  (郑永前)
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Corresponding author

Correspondence to Ke-na Tong  (童科娜).

Additional information

Foundation item: the National Natural Science Foundation of China (No. 71071115) and the National High Technology Research and Development Program (863) of China (No. 2009AA043000)

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Tong, Kn., Xu, Kl. & Zheng, Yq. Sequencing mixed-model flexible assembly lines with variable launching intervals. J. Shanghai Jiaotong Univ. (Sci.) 18, 460–467 (2013). https://doi.org/10.1007/s12204-013-1420-3

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  • DOI: https://doi.org/10.1007/s12204-013-1420-3

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