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A Cost-Driven Mathematical Model and Heuristic Approach for Parallel Assembly Lines with Heterogeneous Workforce

Year 2020, , 418 - 431, 03.06.2020
https://doi.org/10.36306/konjes.661675

Abstract

With the developing technologies, it has become possible for people, machines and robots
to work collaboratively in production environments. In particular, the collaborative working model has
created an opportunity to evaluate the concept of Industry 4.0 which is the popular title of recent years
and assembly line problem structures under the same roof. In this study, as a part of this development, a
mathematical model which combines parallel assembly line problems and human and robot collaborative
workforce which is an important parameter of Industry 4.0 philosophy is proposed. The mathematical
model was tested for new data sets derived from existing data sets in the parallel assembly lines literature
and the results were analyzed. Then, the same data sets were solved with a different method called
Random Search Method and the results were compared and analyzed. Since there are very few studies
with heterogeneous workforce in Parallel Assembly Line Balancing Problems (PMHDP), it is thought that
this study will provide a new perspective for the assembly lines which are thought to be established under
the concept of industry 4.0.

References

  • Ahmadi, R.H.; Dasu, S.; Tang, C.S., 1992,“The dynamic line allocation problem, Management Science”, 38, 1341-1353.doi.org/10.1287/mnsc.38.9.1341
  • Battaia, O. Dolgui, A., 2013, “A taxonomy of line balancing problems and their solution approaches”, International Journal of Production Economics, 142(2), 259–277.
  • doi.org/10.1016/j.ijpe.2012.10.020
  • Becker, C. Scholl, A., 2006,“A survey on problems and methods in generalized assembly line balancing”, European Journal of Operational Research, Vol. 168, issue 3, 694- 715.doi.org/10.1016/j.ejor.2004.07.023
  • Boysen, N. Fliedner, M. Scholl, A., 2007,“A classification of assembly line balancing problems”, European Journal of Operational Research, 183(2), 674-693.doi.org/10.1016/j.ejor.2006.10.010
  • Boysen, N. Scholl, A., 2009, “A General Solution Framework for Component-Commonality Problems”, Business Research, Volume 2, Issue 1, 86–106.
  • Chakravarty, A.M. Shtub, A., 1988, “Modelling the effects of learning and job enlargement on assembly systems with parallel lines”, International Journal of Production Research, 26, 267- 281.doi.org/10.1080/00207548808947858
  • Chiang, W. C. Kouvelis, P., Urban, T. L., 2007, “Line balancing in a just in time production environment: Balancing multiple U-lines”, IIE Transactions, 39, 347-359.doi.org/10.1080/07408170600838340
  • Çil, Z.A. Mete, S. Özceylan E. Ağpak, K., 2017, “A beam search approach for solving type II robotic parallel assemblyline balancing problem”, Applied Soft Computing, 61, 129– 138.doi.org/10.1016/j.asoc.2017.07.062
  • Daganzo, C. F. Blumenfeld, D. E., 1993, “Assembly system design principles and tradeoffs, International Journal of Production Research”, Volume 32,3, 669-681.doi.org/10.1080/00207549408956959
  • Ellegard, K. Jonsson, D., 1992, “Reflective production in the final assembly of motor vehicles: an emerging Swedish challenge”, International Journal of Operations and Production Management, 12, 117- 133.Doi.org/10.1108/EUM0000000001307
  • Erel, E. Sarin, S.C., 1998, “A survey of the assembly line balancing procedures, Production Planning and Control”, 9, 414–434. doi.org/10.1080/095372898233902
  • Esmaeilian, G.R. Sulaiman, S. Ismail, N. Ahmad, M. Hamedi, M., 2008, “Application of MATLAB to Create Initial Solution for Tabu Search in Parallel Assembly Lines Balancing”, International Journal of Computer Science and Network Security, Vol.8, 132-136.
  • Fogel, D.J., 1995, “Evolutionary Computation: Toward a New Philosophy of Machine Intelligence”, IEEE Press, New York. Freeman, D.R., Jucker, J.V., 1967, “The line balancing problem”, AIIE Transactions, 18(6), 361-364.
  • Ghosh, S., Gagnon, R.J., 1989, “A comprehensive literature review and analysis of the design, balancing and scheduling of assembly systems”, International Journal of Production Research, 27, 637–670. doi.org/10.1080/00207548908942574
  • Gökçen, H., Ağpak, K. Benzer, R., 2006, “Balancing of parallel assembly lines”, International Journal of Production Economics, 103, 600–609.doi.org/10.1016/j.ijpe.2005.12.001
  • Gökçen, H., Ağpak, K., 2004, “Hat Dengelemede Yeni Bir Felsefe: Paralel Montaj Hatlarının Eşzamanlı Dengelenmesi”, Karabük Teknik Eğitim Fakültesi Teknoloji Dergisi, 7(1),181-188.
  • İsmail, N. G. Esmaeilian, R. Hamedi, M. Sulaiman, S., 2011, “Balancing of parallel assembly lines with mixed-model product”, International Conference on Management and Artificial Intelligence, Vol 6, 120-124.
  • Karp, M.R., 1975, “Reducibility among Combinatorial Problems”, Complexity of Computer Computations, 85-103.
  • Kellegöz, T. Toklu, B., 2012, “An efficient branch and bound algorithm for assembly line balancing problems with parallel multi-manned workstations”, Computers&Operations Research, 39, 3344–3360.doi.org/10.1016/j.cor.2012.04.019
  • Kellegöz, T. Toklu, B., 2015, “A priority rule-based constructive heuristic and an improvement method for balancing assembly lines with parallel multi-manned workstations”, International Journal of Production Research, Vol. 53, 3, 736–756.doi.org/10.1080/00207543.2014.920548
  • Küçükçok, İ. Zhang, D.Z., 2015, “Balancing of parallel U-shaped assembly lines”, Computers &Operations Research, 64, 233–244. doi.org/10.1016/j.cor.2015.05.014
  • Küçükçok, İ. Zhang, D.Z., 2016, “Mixed-model parallel two-sided assembly line balancing problem: A flexible agent-based ant colony optimization approach”, Computers & Industrial Engineering, 97, 58–72.doi.org/10.1016/j.cie.2016.04.001
  • Küçükçok, İ. Zhang, D.Z., 2014, “Simultaneous balancing and sequencing of mixed-model parallel twosided assembly lines”, International Journal of Production Research, Vol 52, 12, 3665– 3687.doi.org/10.1080/00207543.2013.879618
  • Lehman, M., 1969, “On criteria for assigning models to assembly lines”, International Journal of Production Research, 7, 269-285.doi.org/10.1080/00207546808929817
  • Li, Y. Wang, H. Yang, Z., 2019, “Type II assembly line balancing problem with multi-operators”, Neural Computing and Applications, 31, 347–357.doi.org/10.1007/s00521-018-3834-1
  • Mamun, A.A. Khaled, A.A. Ali, S.M. Chowdhury, M.M., 2012, “A heuristic approach for balancing mixedmodel assembly line of type I using genetic algorithm”, International Journal of Production Research, Vol. 50, 18, 5106–5116.doi.org/10.1080/00207543.2011.643830
  • Nabil, A. Ismail, G. R. Esmaeilian, Sulaiman S., 2011, “Balancing of parallel assembly lines with mixedmodel product”, 2011 International Conference on Management and Artificial Intelligence, IPEDR Vol.6.
  • Özcan, U. Çerçioğlu, H. Gökçen, H. Toklu, B., 2009, “A Tabu Search Algorithm for the Parallel Assembly Line Balancing Problem”, Gazi University Journal of Science, Cilt 22, 4, 313–323.
  • Özcan, U. Çerçioğlu, H. Gökçen, H. Toklu B., 2010, “Balancing and sequencing of parallel mixed-model assembly lines”, International Journal of Production Research, 48(17), 5089- 5113.doi.org/10.1080/00207540903055735
  • Rabbania, M. Ziaeifara, A. Manavizadehb, N., 2014, “Mixed-model assembly line balancing in assembleto- order environment with considerin express parallel line: problem definition and solution procedure”", International Journal of Computer Integrated Manufacturing, Vol 27, 7, 690– 706.doi.org/10.1080/0951192X.2013.834473
  • Salveson, M.E., 1955, “The Assembly Line Balancing Problem”, Journal of Industrial Engineering, 6, 18- 25.
  • Süer, G.A. Dağlı, C.H., 1994, “A knowledge-based system for selection of resource allocation rules and algorithms”, Handbook of expert system applications in manufacturing: structures and rules, Chapman and Hall, 108-129.
  • Tiaccin, L., 2015, “Coupling agenetic algorithm approach and a discrete event simulator to design mixedmodel un-paced assembly lines with parallel workstations and stochastic task times”, Int. J. Production Economics, 159, 319–333.doi.org/10.1016/j.ijpe.2014.05.005
  • Wyman, F.P. Moberly, L.E., 1971, “An application of simulation to compare production line configurations with failures and repairs”, Proceedings of the 5th conference on winter simulation, 187-196.
  • https://drive.google.com/open?id=1LRLF8jn6Fl3KOuCSb1KtXSTrGqy3KXEf Erişim Tarihi: 24.09.2019, Konu: Paralel Montaj Hattı Veri Setleri.

HETEROJEN İŞGÜCÜNE SAHİP PARALEL MONTAJ HATLARI İÇİN MALİYET YÖNELİMLİ MATEMATİKSEL BİR MODEL VE SEZGİSEL BİR YAKLAŞIM

Year 2020, , 418 - 431, 03.06.2020
https://doi.org/10.36306/konjes.661675

Abstract

Gelişen teknolojiler ile son dönemde insan, makine ve robotların üretim ortamlarında işbirlikçi
şekilde çalışabilmeleri mümkün hale gelmiştir. Özellikle işbirlikçi çalışma modeli, son yılların popüler
başlığı olan Endüstri 4.0 kavramı ile montaj hattı problem yapılarını aynı çatı altında değerlendirme
fırsatını doğurmuştur. Bu çalışmada, bu gelişimin bir parçası olarak literatürde de önemli bir yeri olan
paralel montaj hatları problemleri ve Endüstri 4.0 felsefesinin önemli bir parametresi olan insan ve robot
işbirlikçi işgücünü biraraya getiren bir matematiksel model önerilmiştir. Matematiksel model, paralel
montaj hatları literatüründe bulunan mevcut veri setlerinden türetilen yeni veri setleri için denenmiş ve
sonuçlar analiz edilmiştir. Ardından aynı veri setleri farklı bir çözüm metodu olan Rassal Arama Metodu
(RAM) ile çözülmüş ve sonuçlar karşılaştırılarak analiz edilmiştir. Literatürde Paralel Montaj Hattı
Dengeleme Problemlerinde (PMHDP) heterojen yapıda işgücüne sahip olan çok az sayıda çalışmaya
rastlandığından, yapılan çalışmanın literatüre ve endüstri 4.0 kavramı altında kurulması düşünülen
montaj hatları için yeni bir bakış açısı sağlayacağı düşünülmektedir.

References

  • Ahmadi, R.H.; Dasu, S.; Tang, C.S., 1992,“The dynamic line allocation problem, Management Science”, 38, 1341-1353.doi.org/10.1287/mnsc.38.9.1341
  • Battaia, O. Dolgui, A., 2013, “A taxonomy of line balancing problems and their solution approaches”, International Journal of Production Economics, 142(2), 259–277.
  • doi.org/10.1016/j.ijpe.2012.10.020
  • Becker, C. Scholl, A., 2006,“A survey on problems and methods in generalized assembly line balancing”, European Journal of Operational Research, Vol. 168, issue 3, 694- 715.doi.org/10.1016/j.ejor.2004.07.023
  • Boysen, N. Fliedner, M. Scholl, A., 2007,“A classification of assembly line balancing problems”, European Journal of Operational Research, 183(2), 674-693.doi.org/10.1016/j.ejor.2006.10.010
  • Boysen, N. Scholl, A., 2009, “A General Solution Framework for Component-Commonality Problems”, Business Research, Volume 2, Issue 1, 86–106.
  • Chakravarty, A.M. Shtub, A., 1988, “Modelling the effects of learning and job enlargement on assembly systems with parallel lines”, International Journal of Production Research, 26, 267- 281.doi.org/10.1080/00207548808947858
  • Chiang, W. C. Kouvelis, P., Urban, T. L., 2007, “Line balancing in a just in time production environment: Balancing multiple U-lines”, IIE Transactions, 39, 347-359.doi.org/10.1080/07408170600838340
  • Çil, Z.A. Mete, S. Özceylan E. Ağpak, K., 2017, “A beam search approach for solving type II robotic parallel assemblyline balancing problem”, Applied Soft Computing, 61, 129– 138.doi.org/10.1016/j.asoc.2017.07.062
  • Daganzo, C. F. Blumenfeld, D. E., 1993, “Assembly system design principles and tradeoffs, International Journal of Production Research”, Volume 32,3, 669-681.doi.org/10.1080/00207549408956959
  • Ellegard, K. Jonsson, D., 1992, “Reflective production in the final assembly of motor vehicles: an emerging Swedish challenge”, International Journal of Operations and Production Management, 12, 117- 133.Doi.org/10.1108/EUM0000000001307
  • Erel, E. Sarin, S.C., 1998, “A survey of the assembly line balancing procedures, Production Planning and Control”, 9, 414–434. doi.org/10.1080/095372898233902
  • Esmaeilian, G.R. Sulaiman, S. Ismail, N. Ahmad, M. Hamedi, M., 2008, “Application of MATLAB to Create Initial Solution for Tabu Search in Parallel Assembly Lines Balancing”, International Journal of Computer Science and Network Security, Vol.8, 132-136.
  • Fogel, D.J., 1995, “Evolutionary Computation: Toward a New Philosophy of Machine Intelligence”, IEEE Press, New York. Freeman, D.R., Jucker, J.V., 1967, “The line balancing problem”, AIIE Transactions, 18(6), 361-364.
  • Ghosh, S., Gagnon, R.J., 1989, “A comprehensive literature review and analysis of the design, balancing and scheduling of assembly systems”, International Journal of Production Research, 27, 637–670. doi.org/10.1080/00207548908942574
  • Gökçen, H., Ağpak, K. Benzer, R., 2006, “Balancing of parallel assembly lines”, International Journal of Production Economics, 103, 600–609.doi.org/10.1016/j.ijpe.2005.12.001
  • Gökçen, H., Ağpak, K., 2004, “Hat Dengelemede Yeni Bir Felsefe: Paralel Montaj Hatlarının Eşzamanlı Dengelenmesi”, Karabük Teknik Eğitim Fakültesi Teknoloji Dergisi, 7(1),181-188.
  • İsmail, N. G. Esmaeilian, R. Hamedi, M. Sulaiman, S., 2011, “Balancing of parallel assembly lines with mixed-model product”, International Conference on Management and Artificial Intelligence, Vol 6, 120-124.
  • Karp, M.R., 1975, “Reducibility among Combinatorial Problems”, Complexity of Computer Computations, 85-103.
  • Kellegöz, T. Toklu, B., 2012, “An efficient branch and bound algorithm for assembly line balancing problems with parallel multi-manned workstations”, Computers&Operations Research, 39, 3344–3360.doi.org/10.1016/j.cor.2012.04.019
  • Kellegöz, T. Toklu, B., 2015, “A priority rule-based constructive heuristic and an improvement method for balancing assembly lines with parallel multi-manned workstations”, International Journal of Production Research, Vol. 53, 3, 736–756.doi.org/10.1080/00207543.2014.920548
  • Küçükçok, İ. Zhang, D.Z., 2015, “Balancing of parallel U-shaped assembly lines”, Computers &Operations Research, 64, 233–244. doi.org/10.1016/j.cor.2015.05.014
  • Küçükçok, İ. Zhang, D.Z., 2016, “Mixed-model parallel two-sided assembly line balancing problem: A flexible agent-based ant colony optimization approach”, Computers & Industrial Engineering, 97, 58–72.doi.org/10.1016/j.cie.2016.04.001
  • Küçükçok, İ. Zhang, D.Z., 2014, “Simultaneous balancing and sequencing of mixed-model parallel twosided assembly lines”, International Journal of Production Research, Vol 52, 12, 3665– 3687.doi.org/10.1080/00207543.2013.879618
  • Lehman, M., 1969, “On criteria for assigning models to assembly lines”, International Journal of Production Research, 7, 269-285.doi.org/10.1080/00207546808929817
  • Li, Y. Wang, H. Yang, Z., 2019, “Type II assembly line balancing problem with multi-operators”, Neural Computing and Applications, 31, 347–357.doi.org/10.1007/s00521-018-3834-1
  • Mamun, A.A. Khaled, A.A. Ali, S.M. Chowdhury, M.M., 2012, “A heuristic approach for balancing mixedmodel assembly line of type I using genetic algorithm”, International Journal of Production Research, Vol. 50, 18, 5106–5116.doi.org/10.1080/00207543.2011.643830
  • Nabil, A. Ismail, G. R. Esmaeilian, Sulaiman S., 2011, “Balancing of parallel assembly lines with mixedmodel product”, 2011 International Conference on Management and Artificial Intelligence, IPEDR Vol.6.
  • Özcan, U. Çerçioğlu, H. Gökçen, H. Toklu, B., 2009, “A Tabu Search Algorithm for the Parallel Assembly Line Balancing Problem”, Gazi University Journal of Science, Cilt 22, 4, 313–323.
  • Özcan, U. Çerçioğlu, H. Gökçen, H. Toklu B., 2010, “Balancing and sequencing of parallel mixed-model assembly lines”, International Journal of Production Research, 48(17), 5089- 5113.doi.org/10.1080/00207540903055735
  • Rabbania, M. Ziaeifara, A. Manavizadehb, N., 2014, “Mixed-model assembly line balancing in assembleto- order environment with considerin express parallel line: problem definition and solution procedure”", International Journal of Computer Integrated Manufacturing, Vol 27, 7, 690– 706.doi.org/10.1080/0951192X.2013.834473
  • Salveson, M.E., 1955, “The Assembly Line Balancing Problem”, Journal of Industrial Engineering, 6, 18- 25.
  • Süer, G.A. Dağlı, C.H., 1994, “A knowledge-based system for selection of resource allocation rules and algorithms”, Handbook of expert system applications in manufacturing: structures and rules, Chapman and Hall, 108-129.
  • Tiaccin, L., 2015, “Coupling agenetic algorithm approach and a discrete event simulator to design mixedmodel un-paced assembly lines with parallel workstations and stochastic task times”, Int. J. Production Economics, 159, 319–333.doi.org/10.1016/j.ijpe.2014.05.005
  • Wyman, F.P. Moberly, L.E., 1971, “An application of simulation to compare production line configurations with failures and repairs”, Proceedings of the 5th conference on winter simulation, 187-196.
  • https://drive.google.com/open?id=1LRLF8jn6Fl3KOuCSb1KtXSTrGqy3KXEf Erişim Tarihi: 24.09.2019, Konu: Paralel Montaj Hattı Veri Setleri.
There are 36 citations in total.

Details

Primary Language Turkish
Subjects Engineering
Journal Section Research Article
Authors

Serhan Kökhan

Ömer Faruk Baykoç

Selçuk Kürşat İşleyen

Publication Date June 3, 2020
Submission Date December 20, 2019
Acceptance Date January 8, 2020
Published in Issue Year 2020

Cite

IEEE S. Kökhan, Ö. F. Baykoç, and S. K. İşleyen, “HETEROJEN İŞGÜCÜNE SAHİP PARALEL MONTAJ HATLARI İÇİN MALİYET YÖNELİMLİ MATEMATİKSEL BİR MODEL VE SEZGİSEL BİR YAKLAŞIM”, KONJES, vol. 8, no. 2, pp. 418–431, 2020, doi: 10.36306/konjes.661675.