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This paper aims to investigate the part feeding scheduling problem with electric vehicles (EVs) for automotive assembly lines. A point-to-point part feeding model has been formulated to minimize the number of EVs and the maximum handling time by specifying the EVs and sequence of all the delivery tasks.

First, a mathematical programming model of point-to-point part feeding scheduling problem (PTPPFSP) with EVs is presented. Because the PTPPFSP is NP-hard, an improved multi-objective cuckoo search (IMCS) algorithm is developed with novel search strategies, possessing the self-adaptive Levy flights, the Gaussian mutation and elite selection strategy to strengthen the algorithm’s optimization performance. In addition, two local search operators are designed for deep optimization. The effectiveness of the IMCS algorithm is verified by dealing with the PTPPFSP in different problem scales.

Numerical experiments are used to demonstrate how the IMCS algorithm serves as an efficient method to solve the PTPPFSP with EVs. The effectiveness and feasibility of the IMCS algorithm are validated by approximate Pareto fronts obtained from the instances of different problem scales. The computational results show that the IMCS algorithm can achieve better performance than the other high-performing algorithms in terms of solution quality, convergence and diversity.

This study is applicable without regard to the breakdown of EVs. The current research contributes to the scheduling of in-plant logistics for automotive assembly lines, and it could be modified to cope with similar part feeding scheduling problems characterized by just-in-time (JIT) delivery.

Both limited electricity capacity and no earliness and tardiness constraints are considered, and the scheduling problem is solved satisfactorily and innovatively for an efficient JIT part feeding with EVs applied to in-plant logistics.

Automotive robotics R&D and application developments concentrate on methods, tools, and procedures, that enable industry leaders to reduce cost, whilst simultaneously increase quality and productivity. Furthermore, in particular in the USA, manufacturing and assembly system, plant security, safety and reliability, and real‐time performance evaluation and control became key too. The focus is appropriate, since downtime in automotive robotics can mount to typically US$5‐10K, and even to $20K loss per production minute. Introduces some key trends and methods, as well as some implementation examples, showing quality solutions.

GMFanuc Robotics UK operation has burst into the UK robot market with orders for 175 robots. Brian Rooks reports from the company's recently opened premises in Coventry.

The case deals with the unforeseen uncertainties faced by Reva, the first electric car of India, while entering the Indian market. The company was able to take up the challenge of making an energy efficient car. As a new product, Reva achieved operational success, developing an electric, low energy car. Its marketing strategies had limited consumer pull and had to be strengthened to gain consumer acceptance. The ecosystem worldwide is looking for support from governments on the concept and the infrastructure of this product category.

Examines the issues and difficulties of developing a quality costing system in a small engineering company. Four different methods – departmental interviews, process mapping, departmental study, and checklist of cost elements – were used to identify the costs. The value of these methods are commented upon. The main difficulties in developing the quality costing system relate to: a blame culture; a lack of visibility of how people, in particular inspectors, spend their time; and the structure of the accounting system. The majority of the difficulties were addressed by the involvement of senior management, highlighting their importance in the development of a quality costing system.

In a kitting supply system, the occurrence of material-handling errors is unavoidable and will cause serious production losses to an assembly line. To minimize production losses, this paper aims to present a dynamic scheduling problem of automotive assembly line considering material-handling mistakes by integrating abnormal disturbance into the material distribution problem of mixed-model assembly lines (MMALs).

A multi-phase dynamic scheduling (MPDS) algorithm is proposed based on the characteristics and properties of the dynamic scheduling problem. In the first phase, the static material distribution scheduling problem is decomposed into three optimization sub-problems, and the dynamic programming algorithm is used to jointly optimize the sub-problems to obtain the optimal initial scheduling plan. In the second phase, a two-stage rescheduling algorithm incorporating removing rules and adding rules was designed according to the status update mechanism of material demand and multi-load AGVs.

Through comparative experiments with the periodic distribution strategy (PD) and the direct insertion method (DI), the superiority of the proposed dynamic scheduling strategy and algorithm is verified.

To the best of the authors’ knowledge, this study is the first to consider the impact of material-handling errors on the material distribution scheduling problem when using a kitting strategy. By designing an MPDS algorithm, this paper aims to maximize the absorption of the disturbance caused by material-handling errors and reduce the production losses of the assembly line as well as the total cost of the material transportation.

The purpose of this paper is to provide an understanding of how the materials feeding design at a workstation impacts the assembly process performance, in terms of manufacturing flexibility, process support, materials planning and work task efficiency.

The empirical data are based on two embedded case studies performed in close corporation with two Swedish automotive companies; additional observations from more than 20 company visits in Japan, and small‐scale case studies performed in Japanese companies. To fully assess the work measurement figures, video recordings, work instructions and layout drawings were used to plot the operators' walking patterns, and it was then possible to map the whole work cycle for an operator. Industrial engineers, managers, group leaders, team leaders and operators were interviewed. Based on the literature review and personal experience from the small‐scale case studies carried out in Japan, the existing assembly systems' component racks were conceptually re‐designed. This led to two hypothetical assembly systems, which could be used for understanding the impact of materials feeding design on assembly process performance. The design of the new component racks and the choice of packaging types were made together with practitioners.

The paper shows that the design of component racks and choice of packaging types have a major impact on the assembly process performance. Component racks with a large depth and small width and tailored packages create important advantages over traditional Swedish component racks designed for EUR‐pallets. Line stocking is not always the best choice for materials feeding, but this paper shows that line stocking, especially in Swedish assembly systems, can be improved. Sequencing can thus be reduced, resulting in fewer problems when there are sequence breaks in the production flow. Component racks with small packages and large depth increase the work task efficiency, volume, mix, new products and modification flexibility. For example, free space is an important issue for these types of flexibilities. Component racks that are portable and easy to rearrange, together with free space, greatly facilitate handling of new product introductions or modifications of products. The new and old component can be displayed and fed to the same workstation, and if there is a larger change a whole segment of a component rack can easily be replaced by a new one between work shifts.

The scope of the study is limited to the conditions at workstations. Consequences for the materials flow upstream (i.e. internal materials handling, warehousing, transport, supplier processes, etc.) are not included, but must in further studies also be considered to avoid sub‐optimisation.

The paper highlights the fact that a shift in focus is necessary when designing workstations with component racks in Swedish companies, meaning that operators become the customers rather than the transport company or materials handler.

The purpose of this paper is to increase the understanding of the impact of engineering changes on the materials planning process.

This study is based on a conceptual discussion and empirical data from a case study of a supply chain in the automotive industry, including end producers (two OEM companies) and first, second and third tier suppliers.

A framework comprising the situational dimensions of the engineering change was derived from the conceptual discussion and described in terms of product, supply, manufacturing, demand and materials planning characteristics. The empirical study shows the characteristics of the engineering change in the case company and how these have both positive and negative, as well as direct and indirect, influences on the materials scrap, administrative and transport/handling costs. The impact of the actual materials planning strategies is also shown. Another finding was that different engineering change situations exist within the same company. Thus, it is necessary to distinguish between them and to use different planning strategies for each situation. The paper discusses how such differentiated strategies could be developed in the case companies and in general.

The case study focused on a specific product and materials planning situation in the automotive supply chain. Other products and materials planning situations resulting from the same engineering change would have different characteristics and should, therefore, be planned and controlled accordingly. However, the developed framework is a general one.

The appropriateness of a materials planning strategy differs between different engineering change situations. This calls for differentiated materials planning strategies based on the engineering change situation and materials planning characteristics. The framework developed in this paper describes the entire materials planning environment in engineering change situations in order to understand when and how to differentiate materials planning strategies.

This paper fulfils a need for a framework that describes the impact on materials planning from an engineering change perspective. This framework is the first step in the designing of a normative guideline for differentiated materials planning strategies in an engineering change situation.