Developing a multi-objective genetic optimisation approach for an operational design of a manual mixed-model assembly line with walking workers

Al‐Zuheri, Atiya; Luong, Lee; Xing, Ke

doi:10.1007/s10845-014-0934-3

Cited by 27 publications

(16 citation statements)

References 27 publications

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“…In future, it is suggested to embed the human-related objective function in the MMALB optimization. Although there are a few existing studies that considered human-related factors, such as (Rabbani et al, 2016b;Al-Zuheri et al, 2016), the number is still low. Besides, human factors are directly related to the productivity and efficiency of the line, those related to safety and health, are also uncompromised.…”

Section: Discussion and Future Directionsmentioning

confidence: 99%

Recent trend in mixed-model assembly line balancing optimization using soft computing approaches

Razali

Kamarudin

Rashid

et al. 2019

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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.

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Section: Discussion and Future Directionsmentioning

confidence: 99%

Recent trend in mixed-model assembly line balancing optimization using soft computing approaches

Razali

Kamarudin

Rashid

et al. 2019

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“…The balancing problem in MMAL line is more difficult since it must be determined which worker performs which tasks, besides the workstation assignment (Roshani & Giglio, 2017;Roshani et al, 2013). Some studies in the ALBP field of research addressed walking workers or travelling workers option, considering, thus, the possibility that workers travel along the line (Sikora et al, 2017;Nakade & Nishiwaki, 2008;Cevikcan, 2016;Al-Zuheri et al, 2013;Al-Zuheri et al, 2016). But, the ALBP literature mainly considers optimization algorithms used in the design phase of an assembly line with a limited number of different products, aimed at finding the allocation of tasks to workstations, and which worker has to perform them (in the case of walking workers), maximizing an objective function i.e.…”

Section: Assembly Line Balancing Problem (Albp)mentioning

confidence: 99%

The use of labour flexibility for output control in workload controlled flow shops: A simulation analysis

Staudacher¹,

Costa²,

Thürer³

2020

10.5267/j.ijiec

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Workload control theory seeks to align capacity and demand to improve delivery performance. However, workload control researchers mainly focused on input control, which regulates the input of work to the production system, thereby neglecting output control, which uses capacity adjustments to regulate the outflow of the work. Moreover, few existing studies on output control investigate a temporarily increase in capacity. This paper introduces a new search direction for output control which does not require an increase in capacity-labour flexibility. Idle operators can move from their workstation to another, thus temporarily increasing the output of that workstation without extra capacity. Using simulation of a five workstations flow shop line, we highlight the positive performance effect of labour flexibility. However, this comes at the cost of high labour movement. Introducing a load-based constraint on when workers are allowed to move significantly reduces labour movement, while realizing most of the performance improvement observed for unconstrained labour movement. This has important implications for future research and practice.

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“…U-shaped AC design with walking-workers proved to be an effective design against processing time variability, eliminating precise line-balancing issue within the cell. WWALs are also considered by several studies (Al-Zuheri et al , 2013, 2016) that apply ODs. Al-Zuheri et al (2013) analysed the performance of a WWAL for different ODs.…”

Section: Literature Reviewmentioning

confidence: 99%

Response surface approach to robust design of assembly cells through simulation

Aydin

Ozgurler

Durmuşoğlu

et al. 2018

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Purpose This paper aims to present a multi-response robust design (RD) optimization approach for U-shaped assembly cells (ACs) with multi-functional walking-workers by using operational design (OD) factors in a simulation setting. The proposed methodology incorporated the design factors related to the operation of ACs into an RD framework. Utilization of OD factors provided a practical design approach for ACs addressing system robustness without modifying the cell structure. Design/methodology/approach Taguchi’s design philosophy and response surface meta-models have been combined for robust simulation optimization (SO). Multiple performance measures have been considered for the study and concurrently optimized by using a multi-response optimization (MRO) approach. Simulation setting provided flexibility in experimental design selection and facilitated experiments by avoiding cost and time constraints in real-world experiments. Findings The present approach is illustrated through RD of an AC for performance measures: average throughput time, average WIP inventory and cycle time. Findings are in line with expectations that a significant reduction in performance variability is attainable by trading-off optimality for robustness. Reductions in expected performance (optimality) values are negligible in comparison to reductions in performance variability (robustness). Practical implications ACs designed for robustness are more likely to meet design objectives once they are implemented, preventing changes or roll-backs. Successful implementations serve as examples to shop-floor personnel alleviating issues such as operator/supervisor resistance and scepticism, encouraging participation and facilitating teamwork. Originality/value ACs include many activities related to cell operation which can be used for performance optimization. The proposed framework is a realistic design approach using OD factors and considering system stochasticity in terms of noise factors for RD optimization through simulation. To the best of the authors’ knowledge, it is the first time a multi-response RD optimization approach for U-shaped manual ACs with multi-functional walking-workers using factors related to AC operation is proposed.

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Developing a multi-objective genetic optimisation approach for an operational design of a manual mixed-model assembly line with walking workers

Cited by 27 publications

References 27 publications

Recent trend in mixed-model assembly line balancing optimization using soft computing approaches

Recent trend in mixed-model assembly line balancing optimization using soft computing approaches

The use of labour flexibility for output control in workload controlled flow shops: A simulation analysis

Response surface approach to robust design of assembly cells through simulation

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