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Article
Publication date: 9 June 2023

Binghai Zhou and Yufan Huang

The purpose of this paper is to cut down energy consumption and eliminate production waste on mixed-model assembly lines. Therefore, a supermarket integrated dynamic cyclic…

Abstract

Purpose

The purpose of this paper is to cut down energy consumption and eliminate production waste on mixed-model assembly lines. Therefore, a supermarket integrated dynamic cyclic kitting system with the application of electric vehicles (EVs) is introduced. The system resorts to just-in-time (JIT) and segmented sub-line assignment strategies, with the objectives of minimizing line-side inventory and energy consumption.

Design/methodology/approach

Hybrid opposition-based learning and variable neighborhood search (HOVMQPSO), a multi-objective meta-heuristics algorithm based on quantum particle swarm optimization is proposed, which hybridizes opposition-based learning methodology as well as a variable neighborhood search mechanism. Such algorithm extends the search space and is capable of obtaining more high-quality solutions.

Findings

Computational experiments demonstrated the outstanding performance of HOVQMPSO in solving the proposed part-feeding problem over the two benchmark algorithms non-dominated sorting genetic algorithm-II and quantum-behaved multi-objective particle swarm optimization. Additionally, using modified real-life assembly data, case studies are carried out, which imply HOVQMPSO of having good stability and great competitiveness in scheduling problems.

Research limitations/implications

The feeding problem is based on static settings in a stable manufacturing system with determined material requirements, without considering the occurrence of uncertain incidents. Current study contributes to assembly line feeding with EV assignment and could be modified to allow cooperation between EVs.

Originality/value

The dynamic cyclic kitting problem with sub-line assignment applying EVs and supermarkets is solved by an innovative HOVMQPSO, providing both novel part-feeding strategy and effective intelligent algorithm for industrial engineering.

Article
Publication date: 4 July 2023

Binghai Zhou and Mingda Wen

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…

Abstract

Purpose

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).

Design/methodology/approach

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.

Findings

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.

Originality/value

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.

Details

Engineering Computations, vol. 40 no. 5
Type: Research Article
ISSN: 0264-4401

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