MONTAJ HATLARINDA YENİDEN İŞLEME İSTASYON POZİSYONUNUN OPTİMİZASYONU İÇİN BİR KARIŞIK-TAMSAYILI PROGRAMLAMA MODELİ

Yıl 2018, Cilt: 23 Sayı: 3, 273 - 288, 31.12.2018

Fatih Çavdur Elif Kaymaz Aslı Sebatlı

https://doi.org/10.17482/uumfd.420001

Öz

Montaj hatlarında, ürünün önceden belirlenen
birtakım özelliklere uygun olmaması (hatalı olması) durumunda, ürün, hata
giderme çalışmalarının gerçekleştirilmesi için yeniden işleme istasyonuna
gönderilmektedir. Yeniden işleme istasyonuna gönderilen hatalı ürün sayısı ise
montaj hattının hata oranına bağlıdır. Yeniden işleme istasyonunun kullanım
oranının düşük olması durumunda, bu istasyon hata giderme işlemlerine ek olarak
standart görevlerin gerçekleştirilmesi için de kullanılabilir. Yeniden işleme
istasyonunun bu amaçla kullanılması ile hattın çevrim süresi azaltılabilir.
Yeniden işleme istasyonu genellikle montaj hattının sonunda konumlandırılmakla
birlikte, standart görevlerin gerçekleştirilmesi için de kullanılması durumunda
pozisyonunun değiştirilmesi avantajlı olabilir. Bu çalışmada, hata giderme
işlemlerine ek olarak standart görevlerin gerçekleştirilmesi için de kullanılan
bir yeniden işleme istasyonunun dinamik olarak pozisyonunun belirlenmesi ile
çevrim süresini minimize eden bir doğrusal olmayan-karışık-tamsayılı
programlama modeli önerilmektedir. Önerilen modelin doğrusal olmayan yapısı
değişken dönüşümleri ile doğrusal hale dönüştürülmüştür. Yeniden işleme
istasyon pozisyonunun seçimi, görevler arasındaki öncelik ilişkilerine bağlı
olarak bu istasyona atanabilecek olan potansiyel görev sayısını etkilemektedir.
Bu çalışmada, önerilen model kullanılarak yeniden işleme istasyon pozisyonu
optimize edilmektedir. Yeniden işleme istasyonuna atanabilecek olan potansiyel
görev sayısını etkileyen diğer bir faktör de montaj hattı hata oranıdır.
Çalışma kapsamında önerilen model literatürde yer alan farklı örneklemler
kullanılarak test edilmiştir. Problemlerin optimal çözümleri elde edilerek,
sonuçlar analiz edilmiştir.

Anahtar Kelimeler

Montaj hattı dengeleme, Yeniden işleme istasyonu, İstasyon pozisyonu belirlenmesi, Çevrim süresi minimizasyonu, Karışık-tamsayılı programlama

A Mixed-Integer Programming Model for Assembly Line Balancing: Using Rework Station for Standard Tasks and Optimizing Station Position

Öz

In an assembly line, if a product does not meet some
pre-defined specifications (i.e., if it is defective), it is generally sent to a
rework station where necessary correction (rework) operations are performed. On
the other hand, the number of products sent to the rework station for rework operations
depends on the rework (defect) rate of the assembly line. If the defect rate is
relatively low, the rework station can be used to perform standard tasks in
addition to rework operations. Using the rework station for this purpose might
decrease the cycle time of the assembly line. Although rework stations are
generally positioned at the end of an assembly line, it might be advantageous
to change its position if it is also used for performing standard tasks. In
this study, a nonlinear-mixed-integer programming model is proposed to minimize
the cycle time of an assembly line by dynamically positioning the rework
station which is also used to perform standard tasks in addition to rework
operations. The nonlinear structure of the proposed model is linearized using
some variable transformations. The position of the rework station affects the
number of potential tasks assigned to this station depending on the precedence
relationships of the tasks. In this study, the position of the rework station
is optimized using the proposed model. Another factor that affects the number
of potential tasks assigned to the rework station is defect rate of the
assembly line. The proposed model is tested for different defect rates using
some sample problems from the literature. The problems are solved to optimality
and the results are analyzed.

 

Anahtar Kelimeler

Assembly line balancing, Rework station, Determination of station position, Cycle time minimization, Mixed-integer programming

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