MATHEMATICAL PROGRAMMING AND SIMULATION MODELING BASED SOLUTION APPROACH TO WORKER ASSIGNMENT AND ASSEMBLY LINE BALANCING PROBLEM IN AN ELECTRONICS COMPANY

Öz

This study deals with the problem of the assignment of workers to the stations and the balancing of the assembly line in an electronics company. The approach used to solve this problem consists of two stages. In the first stage, a mathematical model is presented which takes into account the information about which jobs the workers can and cannot do, whether the workers are present during the assignment to the stations, which equipment/ equipments the jobs should be done with, and the stations where these equipments are located and the various assignment constraints related to the jobs. As a result of this model being solved with LINGO optimization software, information about which jobs and workers are assigned to which stations is obtained. In the second stage, the assembly line which is arranged using the information obtained from the first stage, in order to test whether the assembly line reaches the desired production target under real life constraints, ARENA simulation model which takes into consideration the factors such as conveyor movement between stations, intermediate inventory areas and stochastic variability in operation times that could not be considered in the present mathematical model is presented. The results obtained from the simulation model show that under these conditions the output amount is below the production target. Then, a solution is achieved that reaches the desired production target by making improvement suggestions for the current system.

Anahtar Kelimeler

• Assembly Line Balancing,Mathematical Modeling,Worker Assignment,Assignment Constraints,Simulation

BİR ELEKTRONİK FİRMASINDAKİ İŞÇİ ATAMALI MONTAJ HATTI DENGELEME PROBLEMİNE MATEMATİKSEL PROGRAMLAMA VE BENZETİM MODELLEME TABANLI BİR ÇÖZÜM YAKLAŞIMI

Öz

Bu çalışma, bir elektronik firmasına ilişkin montaj hattında, işçilerin iş istasyonlarına atanması ve montaj hattının dengelenmesi problemini ele almaktadır. Bu problemin çözümü için kullanılan yaklaşım iki aşamadan oluşmaktadır. İlk aşamada, işçilerin hangi iş elemanlarını yapıp hangi iş elemanlarını yapamadıkları, işçilerin iş istasyonlarına atanması sırasında mevcut olup olmadıkları, iş elemanlarının hangi ekipman/ekipmanlar ile yapılması gerektiği ve bu ekipmanların hangi iş istasyonlarında bulundukları bilgilerini ve iş elemanlarına ilişkin çeşitli atama kısıtlarını dikkate alan bir matematiksel model sunulmaktadır. Bu modelin LINGO optimizasyon yazılımı ile çözülmesi sonucunda, iş elemanlarının ve işçilerin hangi iş istasyonlarına atandığı bilgileri elde edilmektedir. İkinci aşamada ise, ilk aşamadan elde edilen bilgileri kullanarak düzenlenen montaj hattının, istenilen üretim hedefine gerçek hayat kısıtları altında ulaşıp ulaşmadığını test etmek için, mevcut matematiksel modelde dikkate alınamayan, iş istasyonları arası konveyör hareketi, ara stok alanları ve işlem sürelerindeki stokastik değişkenlik gibi faktörleri de dikkate alan bir ARENA benzetim modeli sunulmaktadır. Benzetim modelinden elde edilen sonuçlar, bu koşullar altında çıktı miktarının üretim hedefinin altında kaldığını göstermektedir. Daha sonra ise mevcut sisteme ilişkin iyileştirme önerilerinde bulunularak istenilen üretim hedefine ulaşan bir çözüm elde edilmektedir.

Anahtar Kelimeler

• Montaj Hattı Dengeleme,Matematiksel Modelleme,İşçi Atama,Atama Kısıtları,Benzetim

Kaynakça

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