A mixedmodel assembly line of charcoal canister product that is used in an engine system as fuels vapour filter was observed and found that the current production rate of the line does not achieve customer demand even though the company practices buffer stock for two. The remainder of the paper is structured as follows. This paper presents integer programming formulation and. Gupta mcgrawhill professional 16 disassembly background service rate. The mathematical model is solved by using a mathematical programming package called as gamscplex.
Line balancing problem solution, line balancing techniques. Balancing and sequencing versus only balancing in mixed. This study focuses on the simulation of assembly line balancing in an automotive component in a vendor manufacturing company. Disassembly line balancing and disassembly mode have direct effects on the disassembly efficiency and resource utilization. It can be seen from section 3 that the partial disassembly line balancing problem has many characteristics, such as multiple indicators, multiple constraints and uncertainty. Since then, several research papers in the area of line balancing have appeared. Balancing assembly lines is an nphard combinatorial optimization problem 7,8. However, due to the disparity between demands for parts and their yields, there are many inventory problems that arise during the disassembly line balancing process. Research on mixedmodel assembly line balancing problem of. The formulation is based on an algorithm which solves the singlemodel version of the problem. In this chapter, the disassembly line balancing problem dlbp is solved. Gupta mcgrawhill professional 12 disassembly background nwsupper upper bound on the maximum possible number of workstations for n parts p counter variable.
The goal is to achieve the desired output rate with the smallest number of workstations. A constraint slows the process down and results if waiting for downstream operations and excess capacity results in waiting and absorption of fixed cost. A wellknown assembly design problem is assembly line balancing alb, which deals with the allocation of the tasks among workstations so that a given objective function is optimized. Overview of twostage optimal design for disassembly system using multi criteria environmental and economic parts selection for cost, recycling, and co 2. Many of theses problems, more specifically assembly lines balancing and sequencing problems, are known to be nphard. Formulation of integer programming model for balancing and. This variety leads workload variance among other problems resulting in low. Mixedmodel ushaped assembly line balancing problems mmualbp is known to be nphard resulting in it being nearly impossible to obtain an optimal solution for practical problems with deterministic algorithms. Pdf in this paper, we discuss a new problem, the disassembly line balancing problem. We consider a case example involving the endoflife products. Assembly line balancing problem with reduced number of. Decisions associated with line balancing have a direct influence on the costs of production.
This pioneering work offers efficient techniques required to solve problems involving the number of workstations required and the disassembly sequencing of end. Uncertainty has negative effects on mixedmodel assembly line balancing. The present work proposes a more realistic space allocation approach. Simultaneous perspectivebased mixedmodel assembly line. An andor graph is used to model the disassembly alternatives and the precedence relationships among tasks and subassemblies. With this uncertainty, the paper built a mathematical model on mmalbp of type ii, and designed a solving method which is based on ga. However, there are several problem areas in the pre assembly activities and in the final assembly line itself. The borders of the assembly line balancing problem, as classically drawn, are as clear as any other operations research topic in production planning, with welldefined sets of assumptions, parameters, and objective functions.
Salveson 1955 was the first one to present a mathematical fomulation of assembly line balancing problem, in the form of a linear program. The processes used to accomplish the assembly of the components can be divided into three major categories. Arranging stations in a sequence line for the product to move from one station to the next until its completion at the end of the line. For passive case, the following steps should be carried out. The final result is the line optimization and the production growth. The silencer assembly line is studied in this paper which assembles four products. On the other hand, the implications of not appropriately addressing line balancing span across a wide range of issues, from. Objective is to minimize the imbalance between machines or personnel while meeting required output. Heuristics for solving the line balancing problem 51 5. There are many methods or tools to balance the line as well as eliminate wastes. Therefore, computational intelligence solution approaches have been conceived in order to provide. Eryuruk, kalaoglu and baskak, 2008 used two heuristics assembly line balancing techniques known as the ranked positional weight and probabilistic line balancing. Patic i valahia university of targoviste, electrical engineering faculty, romania. Therefore, computational intelligence solution approaches have been conceived in order to.
Disassembly line balancing problem with fixed number of. There is no claim for completeness because only some researchers provide this site with respective material. Two examples from literature are solved and analyzed. Simulation of assembly line balancing in automotive. Field balancing we provide a service for balacing completed assemblies such as fans and blowers inplace. We use uptodate portable instrumentation to perform the balancing, which minimizes machine downtime. And these workstations are within assembly arrange in serially. A production flow line can be an assembly or a fabrication line or even the combination of both, where the standardized. Balancing and modeling provides indepth information on this complex process essential to remanufacturing, recycling, and. The assembly line balancing is used to balance the workload to the different workstations.
There are different types of wip inside the factory. A shortestroute formulation of the mixedmodel assembly line balancing problem is presented. A wellknown assembly design problem is assembly line balancing alb, which deals with the allocation of the tasks among workstations so that a. The book is composed of 29 chapters grouped into three parts entitled disassembly background, disassembly line balancing and further disassembly line considerations which address general aspects concerning disassembly processes, variations of methods and techniques. Line balancing and model sequencing problems are important for an efficient use of such lines. Assembly line balancing problem albp in this section, characteristics of balancing problems considered in the literature are provided and some classification schemes ghosh and gagnon, 1989. An assembly line balancing is to know how tasks are to be assigned to workstations, so that the predetermined goal is achieved. In this paper, a lean line balancing would be studied as a simple tool, but impressive results would be brought. The purpose of this document is to provide fundamental information and to guide the industry on balance as applied to impellers used in air moving systems.
Compared with the problem of complete disassembly line balancing, the partial disassembly line balancing problem is more complex and the solution space is larger. Mixedmodel ushaped assembly line balancing problems with. Assembly systems and line balancing discrete products are assembled from components. Common tasks across models are assumed to exist and these tasks are performed in the same stations. Second, a proposal for a new model able to approach and solve assembly line balancing problems albps is introduced. This paper presents a new evolutionary method called combinatorial optimisation with coincidence algorithm coin being applied to type i problems of mmualbp in a justintime. It contributes to the management of the assembly line and production arrangements, and increases production efficiency. Calculate theoretical minimum number of workstations. In this paper, we identify the issue of unbalanced inventories generated at various workstations of a.
Modeling and optimization of multiobjective partial. Line balancing line balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. Mixed assembly line balancing method in scenarios with. Column generation approach for disassembly line balancing l. The results of the disassembly line balancing problem dlbp are used as input to the proposed dynamic kanban system for disassembly line dksdl. Lean line balancing for an electronics assembly line. Balancing and modeling provides indepth information on this complex process essential to remanufacturing, recycling, and environmentally conscious manufacturing. A manual assembly line balancing was done by all the three methods of lcr, kwc and rpw and was found that rpw provided the best results with a. The assembly line balancing is help us to increase the efficiency, product and reduces the cost. Finally, a comparison of the rpwmvm and rpw traditional heuristic applied to the mixed al was held.
The time and space assembly line balancing problem. Balance the line by assigning specific tasks to workstations. Mechanical balance of impellers for fans section 1. Heuristic methods for the mixedmodel assembly line. Balancing disassembly line in product recovery to promote the. Assembly line balancing is a hard problem concerned with the assignment of individual work elements or tasks to workstations so as to minimize the assembly cost as much as possible. The objective of balancing the disassembly line is to utilize the disassembly line in an optimized fashion while meeting the demand for the parts retrieved from the returned products. The book is composed of 29 chapters grouped into three parts entitled disassembly background, disassemblyline balancing and further disassemblyline considerations which address general aspects concerning disassembly processes, variations of methods and techniques.
This pioneering work offers efficient techniques required to solve problems involving the number of workstations required and the disassembly sequencing of endoflife products on the disassembly line. A production flow line can be an assembly or a fabrication line or even the. Modeling operational behavior of a disassembly line drs. Minimization of the number of workstations and maximization of the production rate are the most common goals. Scholl and becker, 2006 ghosh and gagnon 1989 classified the albp into four categories are given. Inplace balancing, when possible, saves time and expense of removing the rotor and sending it to a balancing machine. Bricker shuwhwey juang department of industrial engineering the university of iowa working paper november 1993 abstract. Were applied to solve the problem of multimodel assembly line balancing. The processes used to accomplish the assembly of the components can be divided into three major.
Disassembly line balancing and sequencing under uncertainty. To improve the assembly line, many ways can be done. It includes terminology used and methods of balancing practiced by the industry. A mathematical programming model of the assembly line balancing problem dennis l. Assign tasks to first workstation, using rules and staying within cycle time. After that, the second stage is to carry out a disassembly line balancing for minimizing the number of stations using the integer programming. Mathematical fonnulatioh ofthe line balancing problem for mixedmodelassembly lines.
The line balancing is the process in which task assign equally to the each station. Column generation approach for disassembly line balancing. Many assembly lines related optimization problems have been tackled by researchers in the last decades due to its relevance for the decision makers within manufacturing industry. Over the years, the design of efficient assembly lines received considerable attention from both companies and academicians. Many of these deviations are internal to the assembly line balancing problem itself, arising from any.
Resource constrained disassembly line balancing problem. In the next section, a model comprising both disassembly task time uncertainty and disassembly alternatives is developed for the problem considered called here. Line balancing is required in most of production lines, but bottleneck point often happens. In this paper we present a dynamic kanban pull system specifically developed for disassembly lines. This process of adapting the production resources to the changing demand patterns is known as shojinka 1. Line balancing is the assignment of work elements to stations in a line. Mixedmodel assembly line mmal is a type of production line where a variety of product models similar to product characteristics are assembled.
A mathematical programming model of the assembly line. Balancing and sequencing versus only balancing in mixed model. A brief history about the development of assembly line balancing problem is presented in this section. Line balancing is divided in areas depending on layout of. Pdf this book is about the disassembly of endoflife products with particular emphasis on methods and techniques for solving the. Multimodel production and assembly line balancing caravans.
Here you can download data sets and codes for diverse assembly line balancing problems provided by researchers. Disassembly line balancing is a multiobjective problem which was found out to be np complete. Heuristic methods for the mixedmodel assembly line balancing. This type of kanban system is much more complex than the traditional kanban system used in assembly lines. In order to make sure the assembly line can get the maximum production per day, the correct arrangement of the assembly line must be create.
The line efficiency at bottleneck situation showed an improvement of 32%, while balancing efficiency increased by 11% due to the better distribution of tasks among the workstations. Given the substantial manual operations associated with disassembly, the. The most critical, is the one between thermoforming line and preassembly line. Jul 19, 2017 many assembly lines related optimization problems have been tackled by researchers in the last decades due to its relevance for the decision makers within manufacturing industry. Disassembly is an indispensable part in remanufacturing process. The time and space assembly line balancing problem tsalbp is a natural evolution of the well known simple assembly line balancing problem that also takes into consideration the space required by the machinery and assembly parts of the product. Whenever a simultaneous production is allowed for the entire tasks in an assembly line, the mixedmodel assembly line balancing problem become more complicated. Emanuel falkenauer 6 define the line balancing problem as, given set of tasks of.