Heuristic procedures for solving the General Assembly Line Balancing Problem with Setups (GALBPS)

The General Assembly Line Balancing Problem with Setups (GALBPS) was recently defined in the literature. It adds sequence-dependent setup time considerations to the classical Simple Assembly Line Balancing Problem (SALBP) as follows: whenever a task is assigned next to another at the same workstation, a setup time must be added to compute the global workstation time, thereby providing the task sequence inside each workstation. This paper proposes over 50 priority-rule-based heuristic procedures to solve GALBPS, many of which are an improvement upon heuristic procedures published to date.

Simple heuristics for the assembly line worker assignment and balancing problem

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Simple heuristics for the assembly line worker assignment and balancing problem

We propose simple heuristics for the assembly line worker assignment and balancing problem. This problem typically occurs in assembly lines in sheltered work centers for the disabled. Different from the well-known simple assembly line balancing problem, the task execution times vary according to the assigned worker. We develop a constructive heuristic framework based on task and worker priority rules defining the order in which the tasks and workers should be assigned to the workstations. We present a number of such rules and compare their performance across three possible uses: as a stand-alone method, as an initial solution generator for meta-heuristics, and as a decoder for a hybrid genetic algorithm. Our results show that the heuristics are fast, they obtain good results as a stand-alone method and are efficient when used as a initial solution generator or as a solution decoder within more elaborate approaches.

A mathematical model for assembly line balancing model to consider disordering sequence of workstations

Purpose – A binary integer programming model for the simple assembly line balancing problem (SALBP), which is well known as SALBP-1, was formulated more than 30 years ago. Since then, a number of researchers have extended the model for the variants of assembly line balancing problem.The model is still prevalent nowadays mainly because of the lower and upper bounds on task assignment. These properties avoid significant increase of decision variables. The purpose of this paper is to use an example to show that the model may lead to a confusing solution. Design/methodology/approach – The paper provides a remedial constraint set for the model to rectify the disordered sequence problem. Findings – The paper presents proof that the assembly line balancing model formulated by Patterson and Albracht may lead to a confusing solution. Originality/value – No one previously has found that the commonly used model is incorrect.

The Two-Interval Line-Segment Problem

In this paper, the NPMLE in the one-dimensional line segment problem is defined and studied, where line segments on the real line through two non-overlapping intervals are observed. The self-consistency equations for the NPMLE are defined and a quick algorithm for solving them is provided. Supnorm weak convergence to a Gaussian process and efficiency of the NPMLE is proved. The problem has a strong geological application in the study of the lifespan of species.

Two extensions for the ALWABP: Parallel stations and collaborative approach

In this article, we introduce two new variants of the Assembly Line Worker Assignment and Balancing Problem (ALWABP) that allow parallelization of and collaboration between heterogeneous workers. These new approaches suppose an additional level of complexity in the Line Design and Assignment process, but also higher flexibility; which may be particularly useful in practical situations where the aim is to progressively integrate slow or limited workers in conventional assembly lines. We present linear models and heuristic procedures for these two new problems. Computational results show the efficiency of the proposed approaches and the efficacy of the studied layouts in different situations. (C) 2012 Elsevier B.V. All rights reserved.

Recent Results on Stability Analysis of an Optimal Assembly Line Balance

Two assembly line balancing problems are addressed. The first problem (called SALBP-1) is to minimize number of linearly ordered stations for processing n partially ordered operations V = {1, 2, ..., n} within the fixed cycle time c. The second problem (called SALBP-2) is to minimize cycle time for processing partially ordered operations V on the fixed set of m linearly ordered stations. The processing time ti of each operation i ∈V is known before solving problems SALBP-1 and SALBP-2. However, during the life cycle of the assembly line the values ti are definitely fixed only for the subset of automated operations V\V . Another subset V ⊆ V includes manual operations, for which it is impossible to fix exact processing times during the whole life cycle of the assembly line. If j ∈V , then operation times tj can differ for different cycles of the production process. For the optimal line balance b of the assembly line with operation times t1, t2, ..., tn, we investigate stability of its optimality with respect to possible variations of the processing times tj of the manual operations j ∈ V .

Fast optimum-predictive control and capacitor voltage balancing strategy for bipolar back-to-back NPC converters in high-voltage direct current transmission systems

Multilevel power converters have been introduced as the solution for high-power high-voltage switching applications where they have well-known advantages. Recently, full back-to-back connected multilevel neutral point diode clamped converters (NPC converter) have been used inhigh-voltage direct current (HVDC) transmission systems. Bipolar-connected back-to-back NPC converters have advantages in long-distance HVDCtransmission systems over the full back-to-back connection, but greater difficulty to balance the dc capacitor voltage divider on both sending and receiving end NPC converters. This study shows that power flow control and dc capacitor voltage balancing are feasible using fast optimum-predictive-based controllers in HVDC systems using bipolar back-to-back-connected five-level NPC multilevel converters. For both converter sides, the control strategytakes in account active and reactive power, which establishes ac grid currents in both ends, and guarantees the balancing of dc bus capacitor voltages inboth NPC converters. Additionally, the semiconductor switching frequency is minimised to reduce switching losses. The performance and robustness of the new fast predictive control strategy, and its capability to solve the DC capacitor voltage balancing problem of bipolar-connected back-to-back NPCconverters are evaluated.

Balanceamento de linhas de produção usando algoritmos genéticos

Aquando da definição de um layout por fluxo de produto, ou linha de produção, é necessário proceder-se à melhor selecção de combinações de tarefas a serem executadas em cada estação / posto de trabalho para que o trabalho seja executado numa sequência exequível e sejam necessárias quantidades de tempo aproximadamente iguais em cada estação / posto de trabalho. Este processo é chamado de balanceamento da linha de produção. Verifica-se que as estações de trabalho e equipamentos podem ser combinados de muitas maneiras diferentes; daí que a necessidade de efectuar o balanceamento das linhas de produção implique a distribuição de actividades sequenciais por postos de trabalho de modo a permitir uma elevada utilização de trabalho e de equipamentos e a minimizar o tempo de vazio. Os problemas de balanceamento de linhas são tipicamente problemas complexos de tratar, devido ao elevado número de combinações possíveis. Entre os métodos utilizados para resolver estes problemas encontram-se métodos de tentativa e erro, métodos heurísticos, métodos computacionais de avaliação de diferentes opções até se encontrar uma boa solução e métodos de optimização. O objectivo deste trabalho passou pelo desenvolvimento de uma ferramenta computacional para efectuar o balanceamento de linhas de produção recorrendo a algoritmos genéticos. Foi desenvolvida uma aplicação que implementa dois algoritmos genéticos, um primeiro que obtém soluções para o problema e um segundo que optimiza essas soluções, associada a uma interface gráfica em C# que permite a inserção do problema e a visualização de resultados. Obtiveram-se resultados exequíveis demonstrando vantagens em relação aos métodos heurísticos, pois é possível obter-se mais do que uma solução. Além disso, para problemas complexos torna-se mais prático o uso da aplicação desenvolvida. No entanto, esta aplicação permite no máximo seis precedências por cada operação e resultados com o máximo de nove estações de trabalho.

Optimizing Product Line Designs: Efficient Methods and Comparisons

We compare a broad range of optimal product line design methods. The comparisons take advantage of recent advances that make it possible to identify the optimal solution to problems that are too large for complete enumeration. Several of the methods perform surprisingly well, including Simulated Annealing, Product-Swapping and Genetic Algorithms. The Product-Swapping heuristic is remarkable for its simplicity. The performance of this heuristic suggests that the optimal product line design problem may be far easier to solve in practice than indicated by complexity theory.

Job rotation in assembly lines employing disabled workers

In this paper we consider the programming of job rotation in the assembly line worker assignment and balancing problem. The motivation for this study comes from the designing of assembly lines in sheltered work centers for the disabled, where workers have different task execution times. In this context, the well-known training aspects associated with job rotation are particularly desired. We propose a metric along with a mixed integer linear model and a heuristic decomposition method to solve this new job rotation problem. Computational results show the efficacy of the proposed heuristics. (C) 2009 Elsevier B.V. All rights reserved.

Aplicação de meta-heurísticas na resolução do problema de balanceamento e designação de trabalhadores com deficiência em linha de produção

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Modelo de simulação computacional para balanceamento de linhas de produção das empresas cerâmicas de São Miguel do Guamá: um estudo de caso

O presente trabalho vem apresentar um modelo de simulação computacional com propósito de resolver o problema do balanceamento de linhas de produção de uma fábrica de cerâmica vermelha, pertencente ao polo oleiro-cerâmico de São Miguel do Guamá. Neste sentido, inicialmente é realizada uma pesquisa bibliográfica acerca dos sistemas de eventos discretos, dos métodos de solução para balanceamento de linhas e dos conceitos envolvendo a modelagem e simulação. A metodologia aborda o estudo de caso, sendo este conduzido pelo método proposto por Chwif (1999) no qual abrange 03 (três) macros etapas na condução de um projeto de simulação, sejam a etapa de concepção, implementação e etapa de análise. Com o modelo computacional desenvolvido com base nas características atuais da linha de produção, pode-se descrever o estado atual do processo, identificar a operação gargalo bem como encaminhar propostas de melhorias a partir da construção de 03 cenários. Onde o terceiro cenário apresentou os melhores resultados e, portanto, sendo este o modelo representativo ao balanceamento. Ao final, entende-se como principais contribuições deste trabalho o fato de trazer para dentro da universidade a experiência da aplicação prática da simulação, envolvendo uma indústria de cerâmica vermelha de São Miguel do Guamá e oferecer a indústria desta região uma ferramenta potencial para melhoria de seus processos produtivos.

PCB assembly line assignment:a genetic algorithm approach

Purpose – This paper sets out to study a production-planning problem for printed circuit board (PCB) assembly. A PCB assembly company may have a number of assembly lines for production of several product types in large volume. Design/methodology/approach – Pure integer linear programming models are formulated for assigning the product types to assembly lines, which is the line assignment problem, with the objective of minimizing the total production cost. In this approach, unrealistic assignment, which was suffered by previous researchers, is avoided by incorporating several constraints into the model. In this paper, a genetic algorithm is developed to solve the line assignment problem. Findings – The procedure of the genetic algorithm to the problem and a numerical example for illustrating the models are provided. It is also proved that the algorithm is effective and efficient in dealing with the problem. Originality/value – This paper studies the line assignment problem arising in a PCB manufacturing company in which the production volume is high.

A study of adaptive load balancing algorithms for distributed systems

With the advent of distributed computer systems with a largely transparent user interface, new questions have arisen regarding the management of such an environment by an operating system. One fertile area of research is that of load balancing, which attempts to improve system performance by redistributing the workload submitted to the system by the users. Early work in this field concentrated on static placement of computational objects to improve performance, given prior knowledge of process behaviour. More recently this has evolved into studying dynamic load balancing with process migration, thus allowing the system to adapt to varying loads. In this thesis, we describe a simulated system which facilitates experimentation with various load balancing algorithms. The system runs under UNIX and provides functions for user processes to communicate through software ports; processes reside on simulated homogeneous processors, connected by a user-specified topology, and a mechanism is included to allow migration of a process from one processor to another. We present the results of a study of adaptive load balancing algorithms, conducted using the aforementioned simulated system, under varying conditions; these results show the relative merits of different approaches to the load balancing problem, and we analyse the trade-offs between them. Following from this study, we present further novel modifications to suggested algorithms, and show their effects on system performance.