In a manufacturing industry, mixed model assembly line(MMAL) is preferred in order to meet the variety in product demand. MMAL balancing helps in assembling products with similar characteristics in a random fashion. T...In a manufacturing industry, mixed model assembly line(MMAL) is preferred in order to meet the variety in product demand. MMAL balancing helps in assembling products with similar characteristics in a random fashion. The objective of this work aims in reducing the number of workstations, work load index between stations and within each station. As manual contribution of workers in final assembly line is more, ergonomics is taken as an additional objective function. Ergonomic risk level of a workstation is evaluated using a parameter called accumulated risk posture(ARP), which is calculated using rapid upper limb assessment(RULA) check sheet. This work is based on the case study of an MMAL problem in Rane(Madras) Ltd.(India), in which a problem based genetic algorithm(GA) has been proposed to minimize the mentioned objectives. The working of the genetic operators such as selection, crossover and mutation has been modified with respect to the addressed MMAL problem. The results show that there is a significant impact over productivity and the process time of the final assembled product, i.e., the rate of production is increased by 39.5% and the assembly time for one particular model is reduced to 13 min from existing 18 min. Also, the space required using the proposed assembly line is only 200 m2 against existing 350 m2. Further, the algorithm helps in reducing workers fatigue(i.e., ergonomic friendly).展开更多
Multi-manned assembly line,which is broadly utilized to assemble high volume products such as automobiles and trucks,allows a group of workers to assemble different tasks simultaneously in a multi-manned workstation.T...Multi-manned assembly line,which is broadly utilized to assemble high volume products such as automobiles and trucks,allows a group of workers to assemble different tasks simultaneously in a multi-manned workstation.This additional characteristic of parallel operators increases the complexity of the traditional NP-hard assembly line balancing problem.Hence,this paper formulates the Type-I multi-manned assembly line balancing problem to minimize the total number of workstations and operators,and develops an efficient migrating birds optimization algorithm embedded into an idle time reduction method.In this algorithm,a new decoding mechanism is proposed which reduces the sequence-dependent idle time by some task assignment rules;three effective neighborhoods are developed to make refinement of existing solutions in the bird improvement phases;and temperature acceptance and competitive mechanism are employed to avoid being trapped in the local optimum.Comparison experiments suggest that the new decoding and improvements are effective and the proposed algorithm outperforms the compared algorithms.展开更多
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文摘In a manufacturing industry, mixed model assembly line(MMAL) is preferred in order to meet the variety in product demand. MMAL balancing helps in assembling products with similar characteristics in a random fashion. The objective of this work aims in reducing the number of workstations, work load index between stations and within each station. As manual contribution of workers in final assembly line is more, ergonomics is taken as an additional objective function. Ergonomic risk level of a workstation is evaluated using a parameter called accumulated risk posture(ARP), which is calculated using rapid upper limb assessment(RULA) check sheet. This work is based on the case study of an MMAL problem in Rane(Madras) Ltd.(India), in which a problem based genetic algorithm(GA) has been proposed to minimize the mentioned objectives. The working of the genetic operators such as selection, crossover and mutation has been modified with respect to the addressed MMAL problem. The results show that there is a significant impact over productivity and the process time of the final assembled product, i.e., the rate of production is increased by 39.5% and the assembly time for one particular model is reduced to 13 min from existing 18 min. Also, the space required using the proposed assembly line is only 200 m2 against existing 350 m2. Further, the algorithm helps in reducing workers fatigue(i.e., ergonomic friendly).
基金supported by the National Natural Science Foundation of China(51875421,61803287).
文摘Multi-manned assembly line,which is broadly utilized to assemble high volume products such as automobiles and trucks,allows a group of workers to assemble different tasks simultaneously in a multi-manned workstation.This additional characteristic of parallel operators increases the complexity of the traditional NP-hard assembly line balancing problem.Hence,this paper formulates the Type-I multi-manned assembly line balancing problem to minimize the total number of workstations and operators,and develops an efficient migrating birds optimization algorithm embedded into an idle time reduction method.In this algorithm,a new decoding mechanism is proposed which reduces the sequence-dependent idle time by some task assignment rules;three effective neighborhoods are developed to make refinement of existing solutions in the bird improvement phases;and temperature acceptance and competitive mechanism are employed to avoid being trapped in the local optimum.Comparison experiments suggest that the new decoding and improvements are effective and the proposed algorithm outperforms the compared algorithms.
文摘生产规划过程需要同时考虑装配序列规划(Assembly Sequence Planning,ASP)和装配线平衡(Assembly Line Balancing,ALB)。针对ASP和ALB的多项式复杂程度的非确定性问题(Non-Deterministic Polynomial Hard,NP难题)及二者耦合问题,以产品结构图为基础,结合物料清单(Bill of Material,BOM)层次图构建装配约束矩阵,分析产品内部各子装配体独立装配可行性,并对子装配体分拆以获得可行的装配序列矩阵。其次,以工作站最大装配时间、装配方向和工具切换次数、站间平衡为目标,构建综合ASP和ALB的联合规划模型。提出基于Pareto解集的混合人工鱼群算法(Hybrid Artificial Fish Swarm Algorithm,HAFSA),采用自适应视野串行觅食,减少并行觅食重复搜索。对人工鱼群算法得到的装配序列进行粒子群优化(Particle Swarm Optimization,PSO)操作,提高跳出局部最优的可能。将所提算法应用于某装配实例,与基本AFSA、PSO算法对比,验证算法有效性。
