Abstract: To accelerate the remanufacturing process of electronic waste products, this study designs a partial disassembly line with the multi-robotic station to effectively dispose of excessive wastes. The multi-robotic partial disassembly line is a technical upgrade to the existing manual disassembly line. Balancing optimization can make the disassembly line smoother and more efficient. For partial disassembly line balancing with the multi-robotic station (PDLBMRS), a mixed-integer programming model (MIPM) considering the robotic efficiency differences is established to minimize cycle time, energy consumption and hazard index and to calculate their optimal global values. Besides, an enhanced NSGA-II algorithm (HNSGA-II) is proposed to optimize PDLBMRS efficiently. Finally, MIPM and HNSGA-II are applied to an actual mixed disassembly case of two types of computers, the comparison of the results solved by GUROBI and HNSGA-II verifies the correctness of the model and excellent performance of the algorithm, and the obtained Pareto solution set provides multiple options for decision-makers.
Abstract: This study aims to investigate the balancing of the number of operators (Line Balancing technique) in the production line of hard disk drive components in order to increase efficiency. At present, the trend of using hard disk drives has continuously declined leading to limits in a company’s revenue potential. It is important to improve and develop the production process to create market share and to have the ability to compete with competitors with a higher value and quality. Therefore, an effective tool is needed to support such matters. In this research, the Arena program was applied to analyze the results both before and after the improvement. Finally, the precedent was used before proceeding with the real process. There were 14 work stations with 35 operators altogether in the RA production process where this study was conducted. In the actual process, the average production time was 84.03 seconds per product piece (by timing 30 times in each work station) along with a rating assessment by implementing the Westinghouse principles. This process showed that the rating was 123% underlying an assumption of 5% allowance time. Consequently, the standard time was 108.53 seconds per piece. The Takt time was calculated from customer needs divided by working duration in one day; 3.66 seconds per piece. Of these, the proper number of operators was 30 people. That meant five operators should be eliminated in order to increase the production process. After that, a production model was created from the actual process by using the Arena program to confirm model reliability; the outputs from imitation were compared with the original (actual process) and this comparison indicated that the same output meaning was reliable. Then, worker numbers and their job responsibilities were remodeled into the Arena program. Lastly, the efficiency of production process enhanced from 70.82% to 82.63% according to the target.
Abstract: Six sigma is a framework that is used to identify inefficiency so that the cause of inefficiency will be known and right improvement to overcome cause of inefficiency can be conducted. This paper presents result of implementing six sigma to improve piston assembly line in Manufacturing Laboratory, Universitas Indonesia. Six sigma framework will be used to analyze the significant factor of inefficiency that needs to be improved which causes bottleneck in assembly line. After analysis based on six sigma framework conducted, line balancing method was chosen for improvement to overcome causative factor of inefficiency which is differences time between workstation that causes bottleneck in assembly line. Then after line balancing conducted in piston assembly line, the result is increase in efficiency. Efficiency is shown in the decreasing of Defects per Million Opportunities (DPMO) from 900,000 to 700,000, the increasing of level of labor productivity from 0.0041 to 0.00742, the decreasing of idle time from 121.3 seconds to 12.1 seconds, and the increasing of output, which is from 1 piston in 5 minutes become 3 pistons in 5 minutes.
Abstract: This research aims to develop an algorithm to
generate a schedule of multiple cranes that will maximize load
throughputs in anodizing operation. The algorithm proposed utilizes
an enumerative strategy to search for constant time between
successive loads and crane covering range over baths. The computer
program developed is able to generate a near-optimal crane schedule
within reasonable times, i.e. within 10 minutes. Its results are
compared with existing solutions from an aluminum extrusion
industry. The program can be used to generate crane schedules for
mixed products, thus allowing mixed-model line balancing to
improve overall cycle times.
Abstract: One of the most famous techniques which affect the
efficiency of a production line is the assembly line balancing (ALB)
technique. This paper examines the balancing effect of a whole
production line of a real auto glass manufacturer in three steps. In the
first step, processing time of each activity in the workstations is
generated according to a practical approach. In the second step, the
whole production process is simulated and the bottleneck stations
have been identified, and finally in the third step, several
improvement scenarios are generated to optimize the system
throughput, and the best one is proposed. The main contribution of
the current research is the proposed framework which combines two
famous approaches including Assembly Line Balancing and
Optimization via Simulation technique (OvS). The results show that
the proposed framework could be applied in practical environments,
easily.
Abstract: Assembly line balancing problem is aimed to divide
the tasks among the stations in assembly lines and optimize some
objectives. In assembly lines the workload on stations is different
from each other due to different tasks times and the difference in
workloads between stations can cause blockage or starvation in some
stations in assembly lines. Buffers are used to store the semi-finished
parts between the stations and can help to smooth the assembly
production. The assembly line balancing and buffer sizing problem
can affect the throughput of the assembly lines. Assembly line
balancing and buffer sizing problems have been studied separately in
literature and due to their collective contribution in throughput rate of
assembly lines, balancing and buffer sizing problem are desired to
study simultaneously and therefore they are considered concurrently
in current research. Current research is aimed to maximize
throughput, minimize total size of buffers in assembly line and
minimize workload variations in assembly line simultaneously. A
multi objective optimization objective is designed which can give
better Pareto solutions from the Pareto front and a simple example
problem is solved for assembly line balancing and buffer sizing
simultaneously. Current research is significant for assembly line
balancing research and it can be significant to introduce optimization
approaches which can optimize current multi objective problem in
future.
Abstract: This paper combines the branch-and-bound method and the petri net to solve the two-sided assembly line balancing problem, thus facilitating effective branching and pruning of tasks. By integrating features of the petri net, such as reachability graph and incidence matrix, the propose method can support the branch-and-bound to effectively reduce poor branches with systematic graphs. Test results suggest that using petri net in the branching process can effectively guide the system trigger process, and thus, lead to consistent results.
Abstract: Assembly line balancing is a very important issue in
mass production systems due to production cost. Although many
studies have been done on this topic, but because assembly line
balancing problems are so complex they are categorized as NP-hard
problems and researchers strongly recommend using heuristic
methods. This paper presents a new heuristic approach called the
critical task method (CTM) for solving U-shape assembly line
balancing problems. The performance of the proposed heuristic
method is tested by solving a number of test problems and comparing
them with 12 other heuristics available in the literature to confirm the
superior performance of the proposed heuristic. Furthermore, to
prove the efficiency of the proposed CTM, the objectives are
increased to minimize the number of workstation (or equivalently
maximize line efficiency), and minimizing the smoothness index.
Finally, it is proven that the proposed heuristic is more efficient than
the others to solve the U-shape assembly line balancing problem.
Abstract: As there has been a recognizable transition in
automotive industry from mass production to mass customization,
automobile manufacturers and their suppliers have been seeking ways
for more flexible and efficient processes. Eventually, modular
production is currently being applied to manage the changing orders of
the industry. In this paper, two different modular assembly line
concepts were studied: conveyor line and box assembly line.
Mathematical model for two assembly line concepts were developed
and their production line efficiency were compared as a performance
measure to improve their assembly line balancing.
Abstract: Simulation model is an easy way to build up models
to represent real life scenarios, to identify bottlenecks and to enhance
system performance. Using a valid simulation model may give
several advantages in creating better manufacturing design in order to
improve the system performances. This paper presents result of
implementing a simulation model to design hard disk drive
manufacturing process by applying line balancing to improve both
productivity and quality of hard disk drive process. The line balance
efficiency showed 86% decrease in work in process, output was
increased by an average of 80%, average time in the system was
decreased 86% and waiting time was decreased 90%.
Abstract: We address the balancing problem of transfer lines in
this paper to find the optimal line balancing that minimizes the nonproductive
time. We focus on the tool change time and face
orientation change time both of which influence the makespane. We
consider machine capacity limitations and technological constraints
associated with the manufacturing process of auto cylinder heads.
The problem is represented by a mixed integer programming model
that aims at distributing the design features to workstations and
sequencing the machining processes at a minimum non-productive
time. The proposed model is solved by an algorithm established using
linearization schemes and Benders- decomposition approach. The
experiments show the efficiency of the algorithm in reaching the
exact solution of small and medium problem instances at reasonable
time.