Editorial: Introduction to design and analysis of production systems (original) (raw)
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A transfer line balancing problem by heuristic methods: industrial case studies
The paper deals with the problem of optimal configuration of a type of transfer lines which are equipped with transfer machines. Such machines perform operations with standard modular spindle heads which are activated sequentially. All operations assigned to the same spindle head (block of operations) are executed simultaneously by a set of tools fixed at the spindle head. The quantity of machines and spindle heads used to produce a part with the given productivity rate defines the final cost of the transfer line which must be minimized. To minimize this cost, a combinatorial problem of operations assignment to blocks and machines must be solved. The solution must provide a desired productivity (cycle time), it must also satisfy precedence and compatibility constraints. In this paper, we suggest improved versions of FSIC heuristic algorithm in order to help line designers to solve real-scale industrial problems. Results of computational experiments obtained for industrial cases are ...
HEURISTIC METHODS FOR A TRANSFER LINE BALANCING PROBLEM
The paper deals with optimal load balancing for a type of transfer lines which are used in the mass production of a unique product or a family of similar products. In such lines, the machining operations are realized by machines equipped with standard modular spindle heads. Spindle heads of the same machine are activated sequentially. All operations assigned to the same spindle head (block of operations) are executed simultaneously by a set of tools fixed at the spindle head. The required quantity of equipments (machines and spindle heads) to produce a part with the given productivity rate defines the final cost of the transfer line which must be minimized. The cost minimization can be reached by finding the best assignment of operations to blocks and defining the order of blocks activation at each machine. The solution must provide a desired productivity (cycle time), it must also satisfy precedence and compatibility constraints. Improved versions of COMSOAL based FSIC heuristic al...
Literature review of assembly line balancing problems
The International Journal of Advanced Manufacturing Technology, 2014
Mass production system design is a key for the productivity of an organization. Mass production system can be classified into production line machining a component and production line assembling a product. In this paper, the production line assembling a product, which is alternatively called as assembly line system, is considered. In this system, balancing the assembly line as per a desired volume of production per shift is a challenging task. The main objectives of the assembly line design are to minimize the number of workstations for a given cycle time (type 1), to minimize the maximum of the times of workstations for a given number of workstations (type 2), and so forth. Because this problem comes under combinatorial category, the use of heuristics is inevitable. Development of a mathematical model may also be attempted, which will help researchers to compare the solutions of the heuristics with that of the model. In this paper, an attempt is made to present a comprehensive review of literature on the assembly line balancing. The assembly line balancing problems are classified into eight types based on three parameters, viz. the number of models (single-model and multi-model), the nature of task times (deterministic and probabilistic), and the type of assembly line (straight-type and U-type). The review of literature is organized as per the above classification. Further, directions for future research are also presented.
2012
The concept of mass production essentially involves the assembly of identical or interchangeable parts of components into the final product at different stages and workstations. The relative advantages and disadvantages of mass or flow production are a matter of concern for any mass production industry. How to design an assembly line starting from the work breakdown structure to the final grouping of tasks at work stations has been discussed in this paper using two commonly used procedures namely the Kilbridge-Wester Heuristic approach and the Helgeson-Birnie Approach. Line Balancing (LB) is a classic, well-researched Operations Research (OR) optimization problem of significant industrial importance. The specific objectives of this paper is to optimize crew size, system utilization, the probability of jobs being completed within a certain time frame and system design costs. These objectives are addressed simultaneously, and the results obtained are compared with those of single-obje...
In this review paper, we have studied various recent research articles of different authors for finding out the parameters, variables and factors which affects the productivity of a manufacturing organization. Line balancing is a method which is frequently used in manufacturing units to arrange the workstations in a proper sequence and to minimize the number of workstations. Line balancing algorithms help in improving the line efficiency which in turn increases the productivity of the manufacturing unit. Work S tudy and Lean Manufacturing Methods, Industrial Engineering Tools, Assembly Line Balancing, Time S tudy and Time Measurement and Waste Reduction technologies are identified as the key tools for improvement in the productivity of a manufacturing organization.
IJSRD - International Journal for Scientific Research and Development, 2018
— In this research we aimed to improve a line balancing efficiency of a small scale leather women's handbag manufacturing industry which was having a very poor line efficiency of 40.5%. So much of wastage of time, manpower and recourses were taking place at the organization. The aim of this thesis report was to improve the line efficiency of the organization by using heuristic methods of line balancing i.e. largest candidate rule, Kilbridge & wester column method and rank positional method then we have done a comparative study in the existing factory with line balancing technologies. First of all we calculated the existing line efficiency of the organization mathematically which was found to be 40.5%. Then we applied largest candidate rule (LCR), Kilbridge and wester column (KWC) and rank positional method (RPW) methods of line balancing in the existing factory to balance the sequence and time duration of work elements. We done mathematical analysis and found that by using largest candidate rule method, line efficiency can be increased to 77.09, Kilbridge & wester column method gives 70.70% line efficiency and rank positional weighted method gives 77.09% line efficiency. It is proposed that we can use the largest candidate rule or rank positional method to increase the line efficiency of the existing organization and thus can improve the productivity.
Balancing machining lines: a two-phase heuristic
This paper considers balancing machining lines with parallel machines and sequence-dependent setup times. The goal is to minimize the number of machines for a given cycle time. Such lines are paced, i.e. parts are moved from one station to the next with a given cadence (defined by the line cycle time). At least one machine is installed at each station. Parallel machines are to be used when the corresponding station is overloaded, i.e. the total time of all operations assigned to the station exceeds the line cycle time. Moreover, station workload depends on the sequence in which the operations are executed because the setup times related to the changes and displacements of tools, rotations of the part, etc. In this paper, a heuristic method is proposed for the resolution of this problem. An industrial example is presented and numerical results are reported.