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Article
Publication date: 27 April 2020

Ashish Yadav, Shashank Kumar and Sunil Agrawal

Multi-manned assembly lines are designed to produce large-sized products, such as automobiles. In this paper, a multi-manned assembly line balancing problem (MALBP) is…

Abstract

Purpose

Multi-manned assembly lines are designed to produce large-sized products, such as automobiles. In this paper, a multi-manned assembly line balancing problem (MALBP) is addressed in which a group of workers simultaneously performs different tasks on a workstation. The key idea in this work is to improve the workstation efficiency and worker efficiency of an automobile plant by minimizing the number of workstations, the number of workers, and the cycle time of the MALBP.

Design/methodology/approach

A mixed-integer programming formulation for the problem is proposed. The proposed model is solved with benchmark test problems mentioned in research papers. The automobile case study problem is solved in three steps. In the first step, the authors find the task time of all major tasks. The problem is solved in the second step with the objective of minimizing the cycle time for the sub-tasks and major tasks, respectively. In the third step, the output results obtained from the second step are used to minimize the number of workstations using Lingo 16 solver.

Findings

The experimental results of the automobile case study show that there is a large improvement in workstation efficiency and worker efficiency of the plant in terms of reduction in the number of workstations and workers; the number of workstations reduced by 24% with a cycle time of 240 s. The reduced number of workstations led to a reduction in the number of workers (32% reduction) working on that assembly line.

Practical implications

For assembly line practitioners, the results of the study can be beneficial where the manufacturer is required to increased workstation efficiency and worker efficiency and reduce resource requirement and save space for assembling the products.

Originality/value

This paper is the first to apply a multi-manned assembly line balancing approach in real life problem by considering the case study of an automobile plant.

Details

Benchmarking: An International Journal, vol. 28 no. 5
Type: Research Article
ISSN: 1463-5771

Keywords

Article
Publication date: 20 December 2019

Ashish Yadav, Ramawatar Kulhary, Rupesh Nishad and Sunil Agrawal

Parallel two-sided assembly lines are usually designed to produce large-sized products such as trucks and buses. In parallel two-sided assembly lines, both left and right…

Abstract

Purpose

Parallel two-sided assembly lines are usually designed to produce large-sized products such as trucks and buses. In parallel two-sided assembly lines, both left and right sides of the line are used for manufacturing one or more products on two or more assembly lines located parallel to each other. The purpose of this paper is to develop a new mathematical model for the parallel two-sided assembly line balancing problem that helps to evaluate and validate the balancing operations of the machines such as removal of tools and fixtures and reallocating the operators.

Design/methodology/approach

The proposed approach is explained with the help of an example problem. In all, 22 test problems are formed using the benchmark problems P9, P12, P16 and P24. The results obtained are compared among approaches of the task(s) shared, tool(s) shared and both tool(s) and task(s) shared for effect on efficiency as the performance measure. The solution presented here follows the exact solution procedure that is solved by Lingo 16 solver.

Findings

Based on the experiments, line efficiency decreases when only tools are shared and increases when only tasks are shared. Results indicate that by sharing tasks and tools together, better line efficiency is obtained with less cost of tools and fixtures.

Practical implications

According to the industrial aspect, the result of the study can be beneficial for assembly of the products, where tools and tasks are shared between parallel workstations of two or more parallel lines.

Originality/value

According to the author’s best knowledge, this paper is the first to address the tools and tasks sharing between any pair of parallel workstations.

Details

Assembly Automation, vol. 40 no. 6
Type: Research Article
ISSN: 0144-5154

Keywords

Open Access
Article
Publication date: 13 November 2020

Ashish Dwivedi, Ajay Jha, Dhirendra Prajapati, Nenavath Sreenu and Saurabh Pratap

Due to unceasing declination in environment, sustainable agro-food supply chains have become a topic of concern to business, government organizations and customers. The…

1284

Abstract

Purpose

Due to unceasing declination in environment, sustainable agro-food supply chains have become a topic of concern to business, government organizations and customers. The purpose of this study is to examine a problem associated with sustainable network design in context of Indian agro-food grain supply chain.

Design/methodology/approach

A mixed integer nonlinear programming (MINLP) model is suggested to apprehend the major complications related with two-echelon food grain supply chain along with sustainability aspects (carbon emissions). Genetic algorithm (GA) and quantum-based genetic algorithm (Q-GA), two meta-heuristic algorithms and LINGO 18 (traditional approach) are employed to establish the vehicle allocation and selection of orders set.

Findings

The model minimizes the total transportation cost and carbon emission tax in gathering food grains from farmers to the hubs and later to the selected demand points (warehouses). The simulated data are adopted to test and validate the suggested model. The computational experiments concede that the performance of LINGO is superior than meta-heuristic algorithms (GA and Q-GA) in terms of solution obtained, but there is trade-off with respect to computational time.

Research limitations/implications

In literature, inadequate study has been perceived on defining environmental sustainable issues connected with agro-food supply chain from farmer to final distribution centers. A MINLP model has been formulated as practical scenario for central part of India that captures all the major complexities to make the system more efficient. This study is regulated to agro-food Indian industries.

Originality/value

The suggested network design problem is an innovative approach to design distribution systems from farmers to the hubs and later to the selected warehouses. This study considerably assists the organizations to design their distribution network more efficiently.

Details

Modern Supply Chain Research and Applications, vol. 2 no. 3
Type: Research Article
ISSN: 2631-3871

Keywords

Article
Publication date: 13 February 2017

Sajan T. John, Rajagopalan Sridharan and P.N. Ram Kumar

The purpose of this paper is to develop a mathematical model for the network design of a reverse supply chain in a multi-product, multi-period environment. The emission…

1374

Abstract

Purpose

The purpose of this paper is to develop a mathematical model for the network design of a reverse supply chain in a multi-product, multi-period environment. The emission cost due to transportation activities is incorporated into the model to reduce the total cost of emission and study the significance of inclusion of emission cost on the network design decisions.

Design/methodology/approach

Mixed integer linear programming formulation is used to model the network. The developed model is solved and analysed using the commercial solver LINGO.

Findings

The mathematical model provides a unified design of the network for the entire planning horizon comprising of different periods. A reduction in the total cost of emission is achieved. The analysis of the problem environment shows that the network design decisions significantly vary with the consideration of emission cost.

Research limitations/implications

A single mode of transportation is considered in this study. Also, a single type of vehicle is considered for the transportation purpose.

Practical implications

The developed model can aid the decision makers in making better decisions while reducing the total emission cost. The quantification of the emission cost due to transportation activities is presented in an Indian context and can be used for future studies.

Originality/value

An all-encompassing approach for the design of reverse logistics networks with explicit consideration of product structure and emission cost.

Details

The International Journal of Logistics Management, vol. 28 no. 1
Type: Research Article
ISSN: 0957-4093

Keywords

Book part
Publication date: 12 April 2012

Onder Ondemir and Surendra M. Gupta

Reverse supply chain (RSC) is an extension of the traditional supply chain (TSC) motivated by environmental requirements and economic incentives. TSC management deals with…

Abstract

Reverse supply chain (RSC) is an extension of the traditional supply chain (TSC) motivated by environmental requirements and economic incentives. TSC management deals with planning, executing, monitoring, and controlling a collection of organizations, activities, resources, people, technology, and information as the materials and products move from manufacturers to the consumers. Except for a short warranty period, TSC excludes most of the responsibilities toward the product beyond the point of sale. However, because of growing environmental awareness and regulations (e.g. product stewardship statute), TSC alone is no longer an adequate industrial practice. New regulations and public awareness have forced manufacturers to take responsibilities of products when they reach their end of lives. This has necessitated the creation of an infrastructure, known as RSC, which includes collection, transportation, and management of end-of-life products (EOLPs). The advantages of implementing RSC include the reduction in the use of virgin resources, the decrease in the materials sent to landfills and the cost savings stemming from the reuse of EOLPs, disassembled components, and recycled materials. TSC and RSC together represent a closed loop of materials flow. The whole system of organizations, activities, resources, people, technology, and information flowing in this closed loop is known as the closed-loop supply chain (CLSC).

In RSC, the management of EOLPs includes cleaning, disassembly, sorting, inspecting, and recovery or disposal. The recovery could take several forms depending on the condition of EOLPs, namely, product recovery (refurbishing, remanufacturing, repairing), component recovery (cannibalization), and material recovery (recycling). However, neither the quality nor the quantity of returning EOLPs is predictable. This unpredictable nature of RSC is what makes its management challenging and necessitates innovative management science solutions to control it.

In this chapter, we address the order-driven component and product recovery (ODCPR) problem for sensor-embedded products (SEPs) in an RSC. SEPs contain sensors and radio-frequency identification tags implanted in them at the time of their production to monitor their critical components throughout their lives. By facilitating data collection during product usage, these embedded sensors enable one to predict product/component failures and estimate the remaining life of components as the products reach their end of lives. In an ODCPR system, EOLPs are either cannibalized or refurbished. Refurbishment activities are carried out to meet the demand for products and may require reusable components. The purpose of cannibalization is to recover a limited number of reusable components for customers and internal use. Internal component demand stems from the component requirements in the refurbishment operation. It is assumed that the customers have specific remaining-life requirements on components and products. Therefore, the problem is to find the optimal subset and sequence of the EOLPs to cannibalize and refurbish so that (1) the remaining-life-based demands are satisfied while making sure that the necessary reusable components are extracted before attempting to refurbish an EOLP and (2) the total system cost is minimized. We show that the problem could be formulated as an integer nonlinear program. We then develop a hybrid genetic algorithm to solve the problem that is shown to provide excellent results. A numerical example is presented to illustrate the methodology.

Details

Applications of Management Science
Type: Book
ISBN: 978-1-78052-100-8

Article
Publication date: 6 July 2015

Sajan T John and R Sridharan

– The purpose of this paper is to develop a mathematical model for the design of a multi-stage reverse supply chain.

Abstract

Purpose

The purpose of this paper is to develop a mathematical model for the design of a multi-stage reverse supply chain.

Design/methodology/approach

A mixed-integer linear programming formulation is used to model the network. Different data sets are generated randomly. Lingo, an optimisation package is used to solve the model developed.

Findings

The model is able to provide optimum solutions regarding the number and location of different facilities to be established in the network. The flow of different items through the network is also obtained. Analysis of the results shows the sensitivity of design decisions with respect to the changes in the input parameter value.

Research limitations/implications

The authors consider only a single-product and single-period situation for this study. Further research can be done by considering a multi-product and multi-period situation. Uncertainty in data can also be included for future research.

Practical implications

The developed model can aid the managers in taking optimum decisions regarding the network design of a reverse supply chain. The analysis of the model for the variations in the input parameter values can also help the decision makers to take better decisions in a reverse supply chain.

Originality/value

The present research simultaneously considers two types of product return, namely, end-of-life and end-of-use product return, in a seven stage supply chain. Different recovery options such as recycling and remanufacturing are also incorporated into the model.

Details

Journal of Manufacturing Technology Management, vol. 26 no. 6
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 24 January 2022

Vishwas Dohale, Priya Ambilkar, Angappa Gunasekaran and Vijay Bilolikar

The study attempts to develop a multi-product multi-period (MPMP) aggregate production plan (APP) to fulfill the customers' demand in terms of throughput and lead time for…

Abstract

Purpose

The study attempts to develop a multi-product multi-period (MPMP) aggregate production plan (APP) to fulfill the customers' demand in terms of throughput and lead time for achieving market competence.

Design/methodology/approach

This research proposes an integrated Fuzzy analytical hierarchy process (FAHP), multi-objective linear programming (MOLP), and simulation approach. Initially, FAHP is used to select the essential objectives a firm desires to achieve. Adopting the MOLP, an APP is formulated for the firm under study. Later, the simulation model of a firm is created in a discrete-event simulation (DES) software Arena© to evaluate the applicability of the proposed APP. A comparative analysis of the manufacturing performance levels (namely throughput, lead time, and resource utilization) achieved through the implication of an existing production plan and proposed APP is conducted further.

Findings

The findings from the study depict that the proposed MOLP-based APP can satisfy the customers' requirement (namely throughput and lead time) and improve the level of resource utilization compared with the firm's existing production plan.

Research limitations/implications

The proposed research facilitates researchers and practitioners to understand the process of developing MOLP-based MPMP APP and analyzing its applicability through simulation technique to be utilized for developing APP at their firm.

Originality/value

An integrated FAHP-MOLP-simulation framework is the novel contribution to the literature on production planning. It can be extended to solve strategic, tactical, and operational problems in different domains like service, healthcare, supply chain, logistics, and project management.

Details

Benchmarking: An International Journal, vol. 29 no. 10
Type: Research Article
ISSN: 1463-5771

Keywords

Article
Publication date: 4 February 2020

Ashkan Ayough, Mohammad Hosseinzadeh and Alireza Motameni

Line–cell conversion and rotation of operators between cells are common in lean production systems. Thus, the purpose of this study is to provide an integrated look at…

Abstract

Purpose

Line–cell conversion and rotation of operators between cells are common in lean production systems. Thus, the purpose of this study is to provide an integrated look at these two practices through integrating job rotation scheduling and line-cell conversion problems, as well as investigating the effect of rotation frequency on flow time of a Seru system.

Design/methodology/approach

First, a nonlinear integer programming model of job rotation scheduling problem and line–cell conversion problem (Seru-JRSP) was presented. Then, because Seru-JRSP is NP-hard, an efficient and effective invasive weed optimization (IWO) algorithm was developed. Exploration process of IWO was enhanced by enforcing two shake mechanisms.

Findings

Computations of various sample problems showed shorter flow time and less number of assigned operators in a Seru system scheduled through job rotation. Also, nonlinear behavior of flow time versus number of rotation periods was shown. It was demonstrated that, setting number of rotation frequency to one in line with the literature leads to inferior flow time. In addition, ability of developed algorithm to generate clusters of equivalent solutions in terms of flow time was shown.

Originality/value

In this research, integration of job rotation scheduling and line–cell conversion problems was introduced, considering lack of an integrated look at these two practices in the literature. In addition, a new improved IWO equipped with shake enforcement was introduced.

Details

Assembly Automation, vol. 40 no. 3
Type: Research Article
ISSN: 0144-5154

Keywords

Article
Publication date: 9 November 2015

Christoph H Glock and Taebok Kim

This paper studies a supply chain consisting of multiple suppliers and a single buyer. It considers the case where a set of heterogeneous trucks is used for transporting…

1146

Abstract

Purpose

This paper studies a supply chain consisting of multiple suppliers and a single buyer. It considers the case where a set of heterogeneous trucks is used for transporting products, and develops a mathematical model that coordinates the supply chain. The purpose of this paper is to minimise the costs of producing and delivering a product as well as carbon emissions resulting from transportation. In addition, the authors analyse how imposing a tax on carbon emissions impacts the delivery of products from the suppliers to the buyer.

Design/methodology/approach

It is assumed that heterogeneous vehicles are used for transporting products, which have different performance and cost attributes. A mathematical model that considers both operating costs and carbon emissions from transportation is developed. The impact of vehicle attributes on lot sizing and routing decisions is studied with the help of numerical examples and a sensitivity analysis.

Findings

The analysis shows that considering carbon emissions in coordinating a supply chain leads to changes in the routing of vehicles. It is further shown that if carbon emissions lead to costs, routes are changed in such a way that vehicles travel long distances empty or with a low vehicle load to reduce fuel consumption and therewith emissions.

Research limitations/implications

Several areas for future work are highlighted. The study of alternative supply chain structures, for example structures which include logistics service providers, or the investigation of different functional relationships between vehicle load and emission generation offer possibilities for extending the model.

Originality/value

The paper is one of the first to study the use of heterogeneous vehicles in an inventory model of a supply chain, and one of the few supply chain inventory models that consider ecological aspects.

Details

The International Journal of Logistics Management, vol. 26 no. 3
Type: Research Article
ISSN: 0957-4093

Keywords

Article
Publication date: 3 October 2019

S. Umar Sherif, P. Sasikumar, P. Asokan and J. Jerald

Due to the economic benefits and environmental awareness, most of the battery manufacturing industries in India are interested to redesign their existing supply chain…

Abstract

Purpose

Due to the economic benefits and environmental awareness, most of the battery manufacturing industries in India are interested to redesign their existing supply chain network or to incorporate the effective closed loop supply chain network (CLSCN). The purpose of this paper is to develop CLSCN model with eco-friendly distribution network and also enhance recycling to utilize recycled lead for new battery production. The existing CLSCN model of a battery manufacturing industry considered for case study is customized for attaining economic benefit and environmental safety. Hence, single objective, multi-echelon, multi-period and multi-product CLSCN model with centralized depots (CD) is developed in this work to maximize the profit and reduce the emission of CO2 in transportation.

Design/methodology/approach

The proposed CD has the facility to store new batteries (NB), scrap batteries (SB) and lead ingot. The objective of the proposed research work is to identify potential location of CD using K-means clustering algorithm, to allocate facilities with CD using multi-facility allocation (MFA) algorithm and to minimize overall travel distance by allowing bidirectional flow of materials and products between facilities. The proposed eco-friendly CLSCN-CD model is solved using GAMS 23.5 for optimal solutions.

Findings

The performance of the proposed model is validated by comparing with existing model. The evaluation reveals that the proposed model is better than the existing model. The sensitivity analysis is demonstrated with different rate of return of SB, different proportion of recycled lead and different type of vehicles, which will help the management to take appropriate decision in the context of cost savings.

Originality/value

This research work has proposed single objective, multi echelon, multi period and multi product CLSCN-CD model in the battery manufacturing industry to maximize the profit and reduce the CO2 emission in transportation, by enhancing the bidirectional flow of materials/products between facilities of entire model.

Details

Journal of Advances in Management Research, vol. 17 no. 1
Type: Research Article
ISSN: 0972-7981

Keywords

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