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Article
Publication date: 27 August 2019

Mohd Fadzil Faisae Ab. Rashid, Ahmad Nasser Mohd Rose, Nik Mohd Zuki Nik Mohamed and Fadhlur Rahman Mohd Romlay

This paper aims to propose an improved Moth Flame Optimization (I-MFO) algorithm to optimize the cost-oriented two-sided assembly line balancing (2S-ALB). Prior to the…

Abstract

Purpose

This paper aims to propose an improved Moth Flame Optimization (I-MFO) algorithm to optimize the cost-oriented two-sided assembly line balancing (2S-ALB). Prior to the decision to assemble a new product, the manufacturer will carefully study and optimize the related cost to set up and run the assembly line. For the first time in ALB, the power cost is modeled together with the equipment, set up and labor costs.

Design/methodology/approach

I-MFO was proposed by introducing a global reference flame mechanism to guide the global search direction. A set of benchmark problems was used to test the I-MFO performance. Apart from the benchmark problems, a case study from a body shop assembly was also presented.

Findings

The computational experiment indicated that the I-MFO obtained promising results compared to comparison algorithms, which included the particle swarm optimization, Cuckoo Search and ant colony optimization. Meanwhile, the results from the case study showed that the proposed cost-oriented 2S-ALB model was able to assist the manufacturer in making better decisions for different planning periods.

Originality/value

The main contribution of this work is the global reference flame mechanism for MFO algorithm. Furthermore, this research introduced a new cost-oriented model that considered power consumption in the assembly line design.

Details

Engineering Computations, vol. 37 no. 2
Type: Research Article
ISSN: 0264-4401

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Article
Publication date: 12 April 2011

Dimitris I. Petropoulos and Andreas C. Nearchou

The purpose of this paper is to apply particle swarm optimization (PSO) a known combinatorial optimization algorithm to multi‐objective (MO) balancing of large assembly lines.

Abstract

Purpose

The purpose of this paper is to apply particle swarm optimization (PSO) a known combinatorial optimization algorithm to multi‐objective (MO) balancing of large assembly lines.

Design/methodology/approach

A novel approach based on PSO is developed to tackle the simple assembly line balancing problem (SALBP), a well‐known NP‐hard production and operations management problem. Line balancing is considered for two‐criteria problems utilizing cycle time and workload smoothing as performance criteria, as well as for three‐criteria problems involving the balance delay time of the line together with cycle time and workload smoothing. Emphasis is on seeking a set of diverse Pareto optimal solutions for the bi‐criteria SALBP.

Findings

Experiments carried out on multiple test problems taken from the open literature are reported and discussed. Comparisons between the proposed PSO algorithm and two existing MO population heuristics show a quite promising higher performance for the proposed approach.

Originality/value

Artificial particles (potential solutions “flown” by PSO though hyperspace) are encoded to actual ALB solutions via a novel representation mechanism. A new scheme for generating and maintaining diverse Pareto ALB solutions is proposed. For the case of the two‐criteria ALBPs, the individual objectives are summed to a weighted combination with the weight coefficients being dynamically adapted using a novel weighted aggregation method. This weighted method can be applied on any bi‐criteria optimization problem.

Details

Assembly Automation, vol. 31 no. 2
Type: Research Article
ISSN: 0144-5154

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Article
Publication date: 4 September 2019

Yilmaz Delice

This paper aims to discuss the sequence-dependent forward setup time (FST) and backward setup time (BST) consideration for the first time in two-sided assembly lines…

Abstract

Purpose

This paper aims to discuss the sequence-dependent forward setup time (FST) and backward setup time (BST) consideration for the first time in two-sided assembly lines. Sequence-dependent FST and BST values must be considered to compute all of the operational times of each station. Thus, more realistic results can be obtained for real-life situations with this new two-sided assembly line balancing (ALB) problem with setups consideration. The goal is to obtain the most suitable solution with the least number of mated stations and total stations.

Design/methodology/approach

The complex structure it possesses has led to the use of certain assumptions in most of the studies in the ALB literature. In many of them, setup times have been neglected or considered superficially. In the real-life assembly process, potential setup configurations may exist between each successive task and between each successive cycle. When two tasks are in the same cycle, the setup time required (forward setup) may be different from the setup time required if the same two tasks are in consecutive cycles (backward setup).

Findings

Algorithm steps have been studied in detail on a sample solution. Using the proposed algorithm, the literature test problems are solved and the algorithm efficiency is revealed. The results of the experiments revealed that the proposed approach finds promising results.

Originality/value

The sequence-dependent FST and BST consideration is applied in a two-sided assembly line approach for the first time. A genetic algorithm (GA)-based algorithm with ten different heuristic rules was used in this proposed model.

Details

Assembly Automation, vol. 39 no. 5
Type: Research Article
ISSN: 0144-5154

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Article
Publication date: 1 February 2016

Hamid Yilmaz and Mustafa Yilmaz

Within team-oriented approaches, tasks are assigned to teams before being assigned to workstations as a reality of industry. So it becomes clear, which workers assemble…

Abstract

Purpose

Within team-oriented approaches, tasks are assigned to teams before being assigned to workstations as a reality of industry. So it becomes clear, which workers assemble which tasks.

Design/methodology/approach

Team numbers of the assembly line can increase with the number of tasks, but at the same time, due to physical situations of the stations, there will be limitations of maximum working team numbers in a station. For this purpose, heuristic assembly line balancing (ALB) procedure is used and mathematical model is developed for the problem.

Findings

Well-known assembly line test problems widely used in the literature are solved to indicate the effectiveness and applicability of the proposed approach in practice.

Originality/value

This paper draws attention to ALB problem in which workers have been assigned to teams in advance due to the need for specialized skills or equipment on the line for the first time.

Details

Assembly Automation, vol. 36 no. 1
Type: Research Article
ISSN: 0144-5154

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Article
Publication date: 28 September 2010

Kürşad Ağpak

Cycle time fluctuations in assembly lines are one of the important reasons of re‐balancing. As a result of re‐balancing of assembly lines, it will be necessary to change…

Abstract

Purpose

Cycle time fluctuations in assembly lines are one of the important reasons of re‐balancing. As a result of re‐balancing of assembly lines, it will be necessary to change task sequences or equipment locations. The purpose of this paper is to find the task sequence which enables assembly line balancing (ALB) with minimum number of stations (NS) for different cycle times such that tasks and equipment or fixture locations remain unchanged.

Design/methodology/approach

In this paper a heuristic which consist of two stages is proposed to find a common task sequence for different cycle times in assembly lines.

Findings

It is shown that optimal NS for different cycle times can be achieved with a fixed task sequence.

Research limitations/implications

The approach is limited to a single model case. Model variety together with cycle time variety can be investigated in further studies.

Practical implications

Assembly lines which require less time and cost for re‐balancing can be easily designed by the proposed approach.

Originality/value

ALB problem is handled with a new viewpoint. Also, it is observed that the proposed approach serves as a bridge between assembly line design and balancing. In this regard, it is thought to have an important place in the ALB literature.

Details

Assembly Automation, vol. 30 no. 4
Type: Research Article
ISSN: 0144-5154

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Book part
Publication date: 11 August 2014

Daina Cheyenne Harvey and Andrew Varuzzo

William R. Freudenburg conceived “the double diversion” as the simultaneous process of diverting environmental resources or rights shared by all to a small group of social…

Abstract

William R. Freudenburg conceived “the double diversion” as the simultaneous process of diverting environmental resources or rights shared by all to a small group of social actors, which was made possible by a second diversion – the acceptance of the taken-for-granted assumption that environmental harms benefit the common good. In doing so, Freudenburg was among the first to note the importance of looking at not only the distribution of environmental harms but also environmental privileges. In this chapter, we extend the conceptualization of the double diversion to include an instance where rather than framing environmental harm as being a public good, environmental action is framed as benefiting the public writ large, while larger issues of environmental injustice are ignored. In particular, we look at the disproportionate distribution of the urban tree canopy in Worcester, Massachusetts, and the framing of the mitigation of the environmental threat of the Asian Longhorned Beetle as a problem for the commons. Through an analysis of media, we demonstrate that organizations and social actors who have tried to address the effects of this particular ecological threat have nonetheless ignored previous disproportionalities in the environment–society relationship.

Details

William R. Freudenburg, A Life in Social Research
Type: Book
ISBN: 978-1-78190-734-4

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Article
Publication date: 2 February 2015

Hamid Yilmaz and Mustafa Yilmaz

The purpose of this paper is balancing multi-manned assembly lines with load-balancing constraints in addition to conventional ones Most research works about the…

Abstract

Purpose

The purpose of this paper is balancing multi-manned assembly lines with load-balancing constraints in addition to conventional ones Most research works about the multi-manned assembly line balancing problems are focused on the conventional industrial measures that minimize total number of workers, number of multi-manned workstations or both.

Design/methodology/approach

This paper provides a remedial constraint for the model to balance task load density for each worker in workstations.

Findings

Comparisons between the proposed mathematical model and the existing multi-manned mathematical model show a quite promising better task load density performance for the proposed approach.

Originality/value

In this paper, a mathematical model that combines the minimization of multi-manned stations, worker numbers and difference of task load density of workers is proposed for the first time.

Details

Assembly Automation, vol. 35 no. 1
Type: Research Article
ISSN: 0144-5154

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Article
Publication date: 12 September 2016

Ferit Ficici

The paper aims to describe the Taguchi design method-based abrasive wear modeling of in situ AlB2 flake reinforced Al-4Cu matrix alloy composites.

Abstract

Purpose

The paper aims to describe the Taguchi design method-based abrasive wear modeling of in situ AlB2 flake reinforced Al-4Cu matrix alloy composites.

Design/methodology/approach

The abrasive wear behaviors of the composite samples were investigated using pin-on-disk method where the samples slid against different sizes of SiC abrasive grits under various testing conditions. The orthogonal array, signal-to-noise (S/N) ratio and analysis of variance were used to study the optimal testing parameters on composite samples.

Findings

The weight loss of composites decreased with increasing grit size and percentage reinforcement and increased with increasing sliding speed. The optimum test condition, at which the minimum weight loss is obtained, has been determined to be A3B3C1 levels of the control factors. Deviations between the actual and the predicted S/N ratios for abrasive weight losses are negligibly small with 99.5 per cent confidence level.

Originality/value

This paper fulfils an identification of Taguchi method-based abrasive wear behavior of AlB2/Al-4Cu metal matrix composites produced by squeeze casting under various testing conditions.

Details

Industrial Lubrication and Tribology, vol. 68 no. 6
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 16 January 2019

Muhamad Magffierah Razali, Nur Hairunnisa Kamarudin, Mohd Fadzil Faisae Ab. Rashid and Ahmad Nasser Mohd Rose

This paper aims to review and discuss four aspects of mixed-model assembly line balancing (MMALB) problem mainly on the optimization angle. MMALB is a non-deterministic…

Abstract

Purpose

This paper aims to review and discuss four aspects of mixed-model assembly line balancing (MMALB) problem mainly on the optimization angle. MMALB is a non-deterministic polynomial-time hard problem which requires an effective algorithm for solution. This problem has attracted a number of research fields: manufacturing, mathematics and computer science.

Design/methodology/approach

This paper review 59 published research works on MMALB from indexed journal. The review includes MMALB problem varieties, optimization algorithm, objective function and constraints in the problem.

Findings

Based on research trend, this topic is still growing with the highest publication number observed in 2016 and 2017. The review indicated that the future research direction should focus on human factors and sustainable issues in the problem modeling. As the assembly cost becomes crucial, resource utilization in the assembly line should also be considered. Apart from that, the growth of new optimization algorithms is predicted to influence the MMALB optimization, which currently relies on well-established algorithms.

Originality/value

The originality of this paper is on the research trend in MMALB. It provides the future direction for the researchers in this field.

Details

Engineering Computations, vol. 36 no. 2
Type: Research Article
ISSN: 0264-4401

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Article
Publication date: 3 August 2010

M. Duran Toksarı, Selçuk K. İşleyen, Ertan Güner and Ömer Faruk Baykoç

The purpose of this paper is to describe the introduction of simple assembly line balancing problems (SALBPs) under four joint combinations of two learning effects and two…

Abstract

Purpose

The purpose of this paper is to describe the introduction of simple assembly line balancing problems (SALBPs) under four joint combinations of two learning effects and two deterioration effects.

Design/methodology/approach

In this paper, effects of learning and deterioration are considered simultaneously. By the effects of learning and deterioration, it is meant that the task time of a task is defined by increasing function of its execution start time and position in the sequence.

Findings

It was shown that polynomial solutions can be obtained for SALBP under four joint combinations of two learning effects and two deterioration effects. Furthermore, this paper also discusses the adaptations of the proposed models by using known ALB problem.

Originality/value

In this paper, SALBPs were introduced under four joint combinations of two learning effects and two deterioration effects. Position dependent learning effect and time dependent learning effect were considered for learning effect when linear deterioration effect and non‐linear deterioration effect were taken up.

Details

Assembly Automation, vol. 30 no. 3
Type: Research Article
ISSN: 0144-5154

Keywords

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