Assembly Line Balancing with Resource Dependent Task Times*

Paced assembly lines are widely used in repetitive manufacturing applications. Most previous research on the design of paced lines has assumed that each task along the line can be performed by only one worker (or a fixed number of workers). In many cases, however, task duration times may be reduced by increasing the number of workers or changing the equipment assigned to work stations. Thus, the problem becomes one of assigning resource alternatives (e.g., workers and/or equipment) and tasks to work stations to minimize total cost for a desired production rate. For this problem, we present three procedures. The first formulates the problem as a shortest path problem and guarantees optimality. The second and third are heuristic adaptations of the shortest path procedure that are capable of solving large problems. The procedures are compared in terms of solution quality and computation time on a set of 128 randomly generated problems for which optimal solutions could be found. Our simulation results indicate that the choice of procedure depends on problem complexity and resource costs.     

Optimizing the number of stations in assembly lines under learning for limited production

This paper considers finding the optimal number of stations for an assembly line producing a limited quantity of a new product under learning conditions. This type of production characterizes heavy products (such as airplanes and communication systems) and science-based industries (e.g. laser cutting devices and special equipment for hospitals). These products are manufactured in assembly line fashion in small batches of a few hundred. Since the products are assumed to be totally new to the workers, the learning phenomenon is significant (i.e. task times decrease from cycle to cycle as experience is gained). Therefore, standard balancing methods are no longer applicable. Determining the number of stations has a large effect on the production rate while the actual assignment of tasks to stations helps to fine tune the cycle time. Thus, the number of stations can be regarded as a strategic decision variable . This paper discusses two ways for determining the optimal number of stations, namely as a cost minimization problem and as a profit maximization problem.     

Redundant configuration of automated flow lines based on “Industry 4.0”-technologies

Over the past decades, robots have been heavily used for flow lines to increase productivity and product quality and to relieve workers of repetitive and dangerous tasks. However, despite continuous improvement of robots, the occurrence of failures remains a significant challenge in the operation of automated flow lines. Due to the connection of the stations in a flow line via a material handling system, failures at one station can quickly lead to throughput losses due to blocking and starving of upstream and downstream stations, respectively. To some extent, these throughput losses can be reduced by installing buffers between the stations. However, the installation of buffers requires considerable investments and scarce factory space. Therefore, the minimization of the total number of buffers is one of the primary objectives in flow line planning. Due to the advances of manufacturing technologies that form the foundation of “Industry 4.0”, new solutions to reduce throughput losses caused by equipment failures open up. One solution is a redundant configuration, in which downstream stations automatically take over the operations of failed stations in the event of failure. The throughput loss in these situations mainly depends on the level of redundancy designed into the system. Based on existing methods for the design of automated flow lines, we present two line balancing formulations for the configuration of automated flow lines under consideration of redundancies. The first formulation aims at maximizing the lines’ level of redundancy. The second formulation aims at a balanced allocation of redundancies along the line. To evaluate the presented formulations, we compare the performance with an existing line balancing approach for automated lines. With respect to this approach, improvements of the throughput rate between 3 % and 7 % are achieved.     

The flexible blocking job shop with transfer and set-up times

The Flexible Blocking Job Shop (FBJS) considered here is a job shop scheduling problem characterized by the availability of alternative machines for each operation and the absence of buffers. The latter implies that a job, after completing an operation, has to remain on the machine until its next operation starts. Additional features are sequence-dependent transfer and set-up times, the first for passing a job from a machine to the next, the second for change-over on a machine from an operation to the next. The objective is to assign machines and schedule the operations in order to minimize the makespan. We give a problem formulation in a disjunctive graph and develop a heuristic local search approach. A feasible neighborhood is constructed, where typically a critical operation is moved (keeping or changing its machine) together with some other operations whose moves are “implied”. For this purpose, we develop the theoretical framework of job insertion with local flexibility, based on earlier work of Gröflin and Klinkert on insertion. A tabu search that consistently generates feasible neighbor solutions is then proposed and tested on a larger test set. Numerical results support the validity of our approach and establish first benchmarks for the FBJS.     

Trip packing in petrol stations replenishment

This paper considers a generalized version of the trip packing problem that we encountered as a sub-problem of the petrol stations replenishment problem. In this version we have to assign a number of trips to a fleet composed of a limited number of non-identical tank-trucks. Each trip has a specific duration, working time of vehicles is limited and the net revenue of each trip depends on the truck used. The paper provides a mathematical formulation of the problem and proposes some construction, improvement and neighbourhood search solution heuristics. A set of benchmark problem instances is created in a way that reflects real-life situations and used to analyse the performance of the proposed heuristics. A real-life case is also used to further assess the proposed heuristics.     

Approximability of the subset sum reconfiguration problem

The subset sum problem is a well-known NP-complete problem in which we wish to find a packing (subset) of items (integers) into a knapsack with capacity so that the sum of the integers in the packing is at most the capacity of the knapsack and at least a given integer threshold. In this paper, we study the problem of reconfiguring one packing into another packing by moving only one item at a time, while at all times maintaining the feasibility of packings. First we show that this decision problem is strongly NP-hard, and is PSPACE-complete if we are given a conflict graph for the set of items in which each vertex corresponds to an item and each edge represents a pair of items that are not allowed to be packed together into the knapsack. We then study an optimization version of the problem: we wish to maximize the minimum sum among all packings in a reconfiguration. We show that this maximization problem admits a polynomial-time approximation scheme, while the problem is APX-hard if we are given a conflict graph.     

Constructive procedures to solve 2-dimensional bin packing problems with irregular pieces and guillotine cuts

This paper presents an approach for solving a new real problem in cutting and packing. At its core is an innovative mixed integer programme model that places irregular pieces and defines guillotine cuts. The two-dimensional irregular shape bin packing problem with guillotine constraints arises in the glass cutting industry, for example, the cutting of glass for conservatories. Almost all cutting and packing problems that include guillotine cuts deal with rectangles only, where all cuts are orthogonal to the edges of the stock sheet and a maximum of two angles of rotation are permitted. The literature tackling packing problems with irregular shapes largely focuses on strip packing i.e. minimizing the length of a single fixed width stock sheet, and does not consider guillotine cuts. Hence, this problem combines the challenges of tackling the complexity of packing irregular pieces with free rotation, guaranteeing guillotine cuts that are not always orthogonal to the edges of the stock sheet, and allocating pieces to bins. To our knowledge only one other recent paper tackles this problem. We present a hybrid algorithm that is a constructive heuristic that determines the relative position of pieces in the bin and guillotine constraints via a mixed integer programme model. We investigate two approaches for allocating guillotine cuts at the same time as determining the placement of the piece, and a two phase approach that delays the allocation of cuts to provide flexibility in space usage. Finally we describe an improvement procedure that is applied to each bin before it is closed. This approach improves on the results of the only other publication on this problem, and gives competitive results for the classic rectangle bin packing problem with guillotine constraints.     

Collaborative optimization for metro train scheduling and train connections combined with passenger flow control strategy

For high-frequency metro lines, the excessive travel demand during the peak hours brings a high risk to metro system and a low comfort to passengers, so it is important to consider passenger flow control when designing the metro train scheduling strategy. This paper presents a collaborative optimization method for metro train scheduling and train connections combined with passenger control strategy on a bi-directional metro line. Specifically, the dynamic equations for the train headway and train passenger loads along the metro line, the turnaround operations and the entering/exiting depot operations are considered simultaneously. The proposed collaborative optimization problem is formulated as a mixed integer nonlinear programming model to realise the trade-off among the utilization of trains, passenger flow control strategy and the number of awaiting passengers at platforms, which is further reformulated into mixed integer linear programming (MILP) model. To handle the complexity of this MILP model, a Lagrangian relaxation-based approach is designed to decompose the original problem into two small subproblems, which reduces the computational burden of the original problem and can efficiently find a good solution of the train schedule and train connections problem combined with passenger flow control strategy. The numerical experiments are implemented to investigate the effectiveness of the proposed model and approach, which shows that the proposed model is not sensitive to uncertain passenger demand. Under the proposed collaborative optimization approach, the number of train service connections and the crowding inside stations and carriages with the proper passenger flow control strategy can be evidently balanced, and thereby the operation efficiency and safety of the metro lines are effectively improved.     

Algorithms and time complexity of the request-service problem

Given a number of users each of which provides a set of services with a cost for each service and has a set of requests to be satisfied, the goal of the request-service problem is to find a feasible solution that satisfies all requests of each user with minimum cost. In addition, a feasible solution must satisfy an additional constraint. Specifically, if user A provides a service to user B, B should provide a service back to A either directly or indirectly through other users. In this paper, we studied the complexity of this problem. We show that there exists a polynomial time algorithm that can compute a feasible solution with minimum cost if such a solution exists. However, if a feasible solution does not exist, the problem of maximizing the number of satisfied users (i.e., all requests of the users are satisfied) is NP-hard.     

A solution approach to a synchronisation problem in a JIT production system

Delivering of orders on time, increasing productivity and reducing costs are all challenges that companies have to cope with on a regular basis. Making production lines compatible solves these problems and means a reduction in line stoppages and cycle time. In continuous production systems in which production is carried out in lots, the main ways to ensure an uninterrupted and smooth flow and have a high production rate, are line balancing and synchronising work stations. In this paper, a line stoppage and productivity problem at an automotive factory (Toyota Turkey plant, Sakarya city) is solved by root-cause analysis. Cycle time and in-process inventory inconsistency causes the problem between paint and assembly lines. Different solutions are researched and the most appropriate one is selected and implemented.     

Dynamic Programming and Hill-Climbing Techniques for Constrained Two-Dimensional Cutting Stock Problems

In this paper we propose an algorithm for the constrained two-dimensional cutting stock problem (TDC) in which a single stock sheet has to be cut into a set of small pieces, while maximizing the value of the pieces cut. The TDC problem is NP-hard in the strong sense and finds many practical applications in the cutting and packing area. The proposed algorithm is a hybrid approach in which a depth-first search using hill-climbing strategies and dynamic programming techniques are combined. The algorithm starts with an initial (feasible) lower bound computed by solving a series of single bounded knapsack problems. In order to enhance the first-level lower bound, we introduce an incremental procedure which is used within a top-down branch-and-bound procedure. We also propose some hill-climbing strategies in order to produce a good trade-off between the computational time and the solution quality. Extensive computational testing on problem instances from the literature shows the effectiveness of the proposed approach. The obtained results are compared to the results published by Alvarez-Valdés et al. (2002).     

A new hybrid heuristic algorithm for the Precedence Constrained Production Scheduling Problem: A mining application

In this work we address the Precedence Constrained Production Scheduling Problem (PCPSP), the problem of scheduling tasks in such a way that total profit is maximized, while satisfying conditions such as precedence constraints among tasks and side constraints. A motivation for addressing this problem comes from open-pit mining industry, where the PCPSP seeks to maximize the net present value of an ore deposit by selecting the blocks (tasks) to extract, their extraction periods and their processing options, while satisfying constraints as precedences among blocks, limited availability of operational resources and maximum and/or minimum allowable concentrations of ore-grade or pollutants. Since real-world models have millions of blocks and constraints, the monolithic problem is computationally intractable. This article presents a hybrid heuristic algorithm that combines a rolling horizon decomposition with a block preselection procedure, allowing near-optimal solutions to be quickly determined. The proposed heuristic was tested on all the PCPSP instances of the MineLib library and has shown a significant improvement over the previous reported results. Moreover, a good feasible solution has been found for the instance W23, for which no solution has been previously reported.     

Improving throughput for an electronic assembly line using a constraint analysis methodology

Electronic assembly operations are vital to industries such as telecommunications, computers and consumer electronics. This paper presents a constraint analysis methodology for planning and improving electronic assembly operations that draws on concepts from queueing theory, simulation and production planning. The proposed methodology identifies the operational bottleneck and predicts the utilization, throughput and lead time of the assembly line. It also quantifies the relationship between yields and utilization for the assembly operations. A case study is presented that applies the methodology at an Ericsson, Inc., telecommunications equipment assembly facility. The constraint analysis methodology provided valuable decision support as the managers of Ericsson evaluated the costs and benefits of additional production capacity. Although the focus of this paper is electronic assembly operations, the methodology can be applied to general flow line assembly systems with feedback loops for test and rework under dedicated high-volume production.     

A new three-machine shop scheduling: complexity and approximation algorithm

The paper investigates a new three-machine shop scheduling problem that arises from many production systems, such as the garment assembly line, etc. In such scenarios, each job consists of three operations, each of which has to be non-preemptively processed by one specific machine. In contrast with the classical three-machine shop scheduling, the processing order of the operations of each job is partially restricted. In particular, the first two operations are ordered and all the same for all jobs, while the third operation is not restricted. The objective is to minimize the makespan. We show the problem is NP-hard in the ordinary sense and present a polynomial time approximation algorithm with a worst case performance ratio of $\frac{3}{2}$ .     

Optimal mixed-model sequencing for balanced assembly lines

This paper describes an algorithm for solving optimally, the mixed-model sequencing problem when assembly line stations are balanced for each model. An optimal sequence is obtained with the minimization of the overall assembly line length for zero station idle time.The algorithm incorporates two basic steps. The first involves a search procedure that generates all cycle sequences; i.e. sequences having identical ‘start’ and ‘finish’ positions and whose work content can be executed within a defined station length. The second step uses integer programming (IP) to determine the number and combination of the various cycle sequences, such that the production demand is satisfied.     

Integrated Order Scheduling and Packing

We consider an integrated production–distribution scheduling model in a make‐to‐order supply chain consisting of one supplier and one customer. The supplier receives a set of orders from the customer at the beginning of a planning horizon. The supplier needs to process all the orders at a single production line, pack the completed orders to form delivery batches, and deliver the batches to the customer. Each order has a weight, and the total weight of the orders packed in a batch must not exceed the capacity of the delivery batch. Each delivery batch incurs a fixed distribution cost. The problem is to find jointly a schedule for order processing and a way of packing completed orders to form delivery batches such that the total distribution cost (or equivalently, the number of delivery batches) is minimized subject to the constraint that a given customer service level is guaranteed. We consider two customer service constraints—meeting the given deadlines of the orders; or requiring the average delivery lead time of the orders to be within a given threshold. Several problems of the model with each of those constraints are considered. We clarify the complexity of each problem and develop fast heuristics for the NP‐hard problems and analyze their worst‐case performance bounds. Our computational results indicate that all the heuristics are capable of generating near optimal solutions quickly for the respective problems.     

A 6/5-approximation algorithm for the maximum 3-cover problem

In the maximum cover problem, we are given a collection of sets over a ground set of elements and a positive integer w, and we are asked to compute a collection of at most w sets whose union contains the maximum number of elements from the ground set. This is a fundamental combinatorial optimization problem with applications to resource allocation. We study the simplest APX-hard variant of the problem where all sets are of size at most 3 and we present a 6/5-approximation algorithm, improving the previously best known approximation guarantee. Our algorithm is based on the idea of first computing a large packing of disjoint sets of size 3 and then augmenting it by performing simple local improvements.     

The two-dimensional vector packing problem with piecewise linear cost function

The two-dimensional vector packing problem with piecewise linear cost function (2DVPP-PLC) is a practical problem faced by a manufacturer of children׳s apparel that ships products using courier service. The manufacturer must ship a number of items using standard-sized cartons, where the cost of a carton quoted by the courier is determined by a piecewise linear function of its weight. The cost function is not necessarily convex or concave. The objective is to pack all given items into a set of cartons such that the total delivery cost is minimized while observing both the weight limit and volume capacity constraints. This problem is commonly faced by many manufacturers that ship products using courier service. We formulate the problem as an integer programming model. Since the 2DVPP-PLC generalizes the classical bin packing problem, it is more complex and challenging. Solving it directly using CPLEX is successful only for small instances. We propose a simple heuristic that is extremely fast and produces high-quality solutions for instances of practical size. We develop an iterative local search algorithm to improve the solution quality further. We generate two categories of test data that can serve as benchmark for future research.     

A decision support system for modelling and implementing the supply network configuration and operations scheduling problem in the machine tool industry

This paper presents a decision support system to simultaneously solve the supply network configuration problem and the operations scheduling problem for the machine tool industry. A novel database structure, which is able to consider alternative operations and alternative bills of material, has been used. An algorithm for complete enumeration to determine all the feasible solutions using stroke graphs is introduced. A multiagent-based simulator evaluates the different key performance indicators that the supply network deals with for each alternative solution (e.g. workload, profits, delivery times, etc.) to determine that ‘satisficed’ by the collaborative decision-making among its members. A case study based on a Spanish company that assembles highly customised machines and tools in several European plants is considered. From the experiments results based on data linked to this industry, it will be demonstrated that the tool is potentially useful for stakeholders and for the central decision-maker to make decisions collaboratively in a multisite context case.     

Packing trees in communication networks

Given an undirected edge-capacitated graph and given (possibly) different subsets of vertices, we consider the problem of selecting a maximum (weighted) set of Steiner trees, each tree spanning a subset of vertices, without violating the capacity constraints. This problem is motivated by applications in multicast communication networks. We give an integer linear programming (ILP) formulation for the problem, and observe that its linear programming (LP) relaxation is a fractional packing problem with exponentially many variables and a block (sub-)problem that cannot be solved in polynomial time. To this end, we take an r-approximate block solver (a weak block solver) to develop a (1−ε)/r-approximation algorithm for the LP relaxation. The algorithm has a polynomial coordination complexity for any ε∈(0,1). To the best of our knowledge, this is the first approximation result for fractional packing problems with only weak block solvers (with arbitrarily large approximation ratio) and a coordination complexity that is polynomial in the input size. This leads also to an approximation algorithm for the underlying tree packing problem. Finally, we extend our results to an important multicast routing and wavelength assignment problem in optical networks, where each Steiner tree is to be assigned one of a limited set of given wavelengths, so that trees crossing the same fiber are assigned different wavelengths. A preliminary version of this paper appeared in the Proceedings of the 1st Workshop on Internet and Network Economics (WINE 2005), LNCS, vol. 3828, pp. 688–697. Research supported by a MITACS grant for all the authors, an NSERC post doctoral fellowship for the first author, the NSERC Discovery Grant #5-48923 for the second and fourth author, NSERC Discovery Grant #15296 for the third author, the Canada Research Chair Program for the second author, and an NSERC industrial and development fellowship for the fourth author.