Analyzing the Use of Rework Stations for Parallel Tasks in Assembly Line Balancing via Mathematical Programming and Simulation

Yıl 2022, Cilt: 25 Sayı: 1, 205 - 222, 01.03.2022

Elif Kaymaz Fatih Çavdur

https://doi.org/10.2339/politeknik.717831

Öz

In assembly lines, rework stations are generally used for reprocessing defective items. On the other hand, using rework stations for this purpose only might cause inefficient usage of the resources in this station especially if the defective rate of the assembly line is low. In this study, first, a mixed-integer programming model for cycle time minimization is presented by considering the use of rework stations for parallel tasks. By linearizing the non-linear constraint about parallel tasks using a variate transformation, the model is transformed to a linear-mixed-integer form. Secondly, a novel simulation model is developed in the study for validating the results obtained using the integer programming model by incorporating stochastic problem components. Using the developed model, two sample problems are simulated and the applicability of the integer programming models results are analyzed.

Anahtar Kelimeler

Assembly line balancing, cycle time minimization, parallel task assignment, mixed-integer programming, simulation

Montaj Hattı Dengelemede Yeniden İşleme İstasyonlarının Paralel Görevler için Kullanımının Matematiksel Programlama ve Simülasyon ile Analizi

Öz

Montaj hatlarında yeniden işleme istasyonları genellikle uygun olmayan ürünlerin yeniden işlendiği bir istasyon olarak kullanılmaktadır. Bununla birlikte, yeniden işleme istasyonunun yalnızca bu amaç için kullanılması montaj hattı hata oranının düşük olması durumunda, bu istasyonda bulunan kaynakların verimsiz bir şekilde kullanılmasına neden olabilmektedir. Bu çalışmada, öncelikle, yeniden işleme istasyonunun paralel görevler için kullanılması dikkate alınarak çevrim süresini minimize etmeyi amaçlayan bir doğrusal olmayan karışık-tamsayılı programlama modeli sunulmuştur. Paralel görevlerle ilgili doğrusal-olmayan kısıt, değişken dönüşümü ile doğrusallaştırılarak, model doğrusal-karışık-tamsayılı şekle dönüştürülmüştür. Buna ek olarak, çalışma kapsamında, problemin stokastik unsurları dikkate alınarak, tamsayılı programdan elde edilen sonuçların doğrulanması için de bir simülasyon modeli geliştirilmiştir. Geliştirilen model ile örnek bir problem simüle edilerek, söz konusu problem için tamsayılı programlama modelinden elde edilen çözümün uygulanabilirliği incelenmiştir.

Anahtar Kelimeler

Montaj hattı dengeleme, çevrim süresi minimizasyonu, paralel görev atama, karışık-tamsayılı programlama, simülasyon

Kaynakça

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