IDEAS home Printed from https://ideas.repec.org/a/eee/ejores/v216y2012i3p594-604.html
   My bibliography  Save this article

Resequencing of mixed-model assembly lines: Survey and research agenda

Author

Listed:
  • Boysen, Nils
  • Scholl, Armin
  • Wopperer, Nico

Abstract

Nowadays, mixed-model assembly lines are applied in a wide range of industries to mass-produce customized products to order, e.g., in automobile industry. An important decision problem in this context receiving a lot of attention from researchers and practitioners is the sequencing problem, which decides on the succession of workpieces launched down the line. However, if multiple departments with diverging sequencing objectives are to be passed or unforeseen disturbances like machine breakdowns or material shortages occur, a resequencing of a given production sequence often becomes equally essential. This paper reviews existing research on resequencing in a mixed-model assembly line context. Important problem settings, alternative buffer configurations, and resulting decision problems are described. Finally, future research needs are identified as some relevant real-world resequencing settings have not been dealt with in literature up to now.

Suggested Citation

  • Boysen, Nils & Scholl, Armin & Wopperer, Nico, 2012. "Resequencing of mixed-model assembly lines: Survey and research agenda," European Journal of Operational Research, Elsevier, vol. 216(3), pages 594-604.
    • Handle: RePEc:eee:ejores:v:216:y:2012:i:3:p:594-604
    DOI: 10.1016/j.ejor.2011.08.009
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0377221711007284
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ejor.2011.08.009?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to look for a different version below or search for a different version of it.

    Other versions of this item:

    References listed on IDEAS

    as
    1. Zhi-Long Chen & George L. Vairaktarakis, 2005. "Integrated Scheduling of Production and Distribution Operations," Management Science, INFORMS, vol. 51(4), pages 614-628, April.
    2. Zhi-Long Chen & Nicholas G. Hall, 2007. "Supply Chain Scheduling: Conflict and Cooperation in Assembly Systems," Operations Research, INFORMS, vol. 55(6), pages 1072-1089, December.
    3. A. Agnetis & P. Detti & C. Meloni & D. Pacciarelli, 2001. "Set-Up Coordination between Two Stages of a Supply Chain," Annals of Operations Research, Springer, vol. 107(1), pages 15-32, October.
    4. Prandtstetter, Matthias & Raidl, Günther R., 2008. "An integer linear programming approach and a hybrid variable neighborhood search for the car sequencing problem," European Journal of Operational Research, Elsevier, vol. 191(3), pages 1004-1022, December.
    5. George Steiner & Scott Yeomans, 1993. "Level Schedules for Mixed-Model, Just-in-Time Processes," Management Science, INFORMS, vol. 39(6), pages 728-735, June.
    6. McMullen, P.R. & Tarasewich, Peter, 2005. "A beam search heuristic method for mixed-model scheduling with setups," International Journal of Production Economics, Elsevier, vol. 96(2), pages 273-283, May.
    7. Solnon, Christine & Cung, Van Dat & Nguyen, Alain & Artigues, Christian, 2008. "The car sequencing problem: Overview of state-of-the-art methods and industrial case-study of the ROADEF'2005 challenge problem," European Journal of Operational Research, Elsevier, vol. 191(3), pages 912-927, December.
    8. Boysen, Nils & Fliedner, Malte & Scholl, Armin, 2008. "Assembly line balancing: Which model to use when," International Journal of Production Economics, Elsevier, vol. 111(2), pages 509-528, February.
    9. U. Manoj & Jatinder Gupta & Sushil Gupta & Chelliah Sriskandarajah, 2008. "Supply chain scheduling: Just-in-time environment," Annals of Operations Research, Springer, vol. 161(1), pages 53-86, July.
    10. Nicholas G. Hall & Chris N. Potts, 2003. "Supply chain scheduling: Batching and delivery," Operations Research, INFORMS, vol. 51(4), pages 566-584, August.
    11. Ribeiro, Celso C. & Aloise, Daniel & Noronha, Thiago F. & Rocha, Caroline & Urrutia, Sebastián, 2008. "A hybrid heuristic for a multi-objective real-life car sequencing problem with painting and assembly line constraints," European Journal of Operational Research, Elsevier, vol. 191(3), pages 981-992, December.
    12. Eric Bonabeau & Guy Theraulaz & Jean-Louis Deneubourg, 1998. "Fixed Response Thresholds and the Regulation of Division of Labor in Insect Societies," Working Papers 98-01-009, Santa Fe Institute.
    13. Wieslaw Kubiak & Suresh Sethi, 1991. "A Note on "Level Schedules for Mixed-Model Assembly Lines in Just-in-Time Production Systems"," Management Science, INFORMS, vol. 37(1), pages 121-122, January.
    14. Boysen, Nils & Fliedner, Malte & Scholl, Armin, 2009. "Sequencing mixed-model assembly lines: Survey, classification and model critique," European Journal of Operational Research, Elsevier, vol. 192(2), pages 349-373, January.
    15. Kubiak, Wieslaw, 1993. "Minimizing variation of production rates in just-in-time systems: A survey," European Journal of Operational Research, Elsevier, vol. 66(3), pages 259-271, May.
    16. Cordeau, Jean-François & Laporte, Gilbert & Pasin, Federico, 2008. "Iterated tabu search for the car sequencing problem," European Journal of Operational Research, Elsevier, vol. 191(3), pages 945-956, December.
    17. A Lim & Z Xu, 2009. "Searching optimal resequencing and feature assignment on an automated assembly line," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 60(3), pages 361-371, March.
    18. McMullen, Patrick R., 2001. "A Kohonen self-organizing map approach to addressing a multiple objective, mixed-model JIT sequencing problem," International Journal of Production Economics, Elsevier, vol. 72(1), pages 59-71, June.
    19. Mansouri, S. Afshin, 2005. "A Multi-Objective Genetic Algorithm for mixed-model sequencing on JIT assembly lines," European Journal of Operational Research, Elsevier, vol. 167(3), pages 696-716, December.
    20. Gagne, Caroline & Gravel, Marc & Price, Wilson L., 2006. "Solving real car sequencing problems with ant colony optimization," European Journal of Operational Research, Elsevier, vol. 174(3), pages 1427-1448, November.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Boysen, Nils & Stephan, Konrad, 2016. "A survey on single crane scheduling in automated storage/retrieval systems," European Journal of Operational Research, Elsevier, vol. 254(3), pages 691-704.
    2. Maximilian Stauder & Niklas Kühl, 2022. "AI for in-line vehicle sequence controlling: development and evaluation of an adaptive machine learning artifact to predict sequence deviations in a mixed-model production line," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 709-747, September.
    3. Elif Elcin Gunay & Ufuk Kula, 2017. "A stochastic programming model for resequencing buffer content optimisation in mixed-model assembly lines," International Journal of Production Research, Taylor & Francis Journals, vol. 55(10), pages 2897-2912, May.
    4. Boysen, Nils & Emde, Simon & Hoeck, Michael & Kauderer, Markus, 2015. "Part logistics in the automotive industry: Decision problems, literature review and research agenda," European Journal of Operational Research, Elsevier, vol. 242(1), pages 107-120.
    5. Quetschlich, Mathias & Moetz, André & Otto, Boris, 2021. "Optimisation model for multi-item multi-echelon supply chains with nested multi-level products," European Journal of Operational Research, Elsevier, vol. 290(1), pages 144-158.
    6. Taube, F. & Minner, S., 2018. "Resequencing mixed-model assembly lines with restoration to customer orders," Omega, Elsevier, vol. 78(C), pages 99-111.
    7. Maico Roris Severino & Moacir Godinho Filho, 2019. "POLCA system for supply chain management: simulation in the automotive industry," Journal of Intelligent Manufacturing, Springer, vol. 30(3), pages 1271-1289, March.
    8. Moreira, Mayron César O. & Costa, Alysson M., 2013. "Hybrid heuristics for planning job rotation schedules in assembly lines with heterogeneous workers," International Journal of Production Economics, Elsevier, vol. 141(2), pages 552-560.
    9. Marcel Lehmann & Heinrich Kuhn, 2020. "Modeling and analyzing sequence stability in flexible automotive production systems," Flexible Services and Manufacturing Journal, Springer, vol. 32(2), pages 366-394, June.
    10. Abolfazl Jafari Asl & Maghsud Solimanpur & Ravi Shankar, 2019. "Multi-objective multi-model assembly line balancing problem: a quantitative study in engine manufacturing industry," OPSEARCH, Springer;Operational Research Society of India, vol. 56(3), pages 603-627, September.
    11. Boysen, Nils & Stephan, Konrad & Schwerdfeger, Stefan, 2024. "Order consolidation in warehouses: The loop sorter scheduling problem," European Journal of Operational Research, Elsevier, vol. 316(2), pages 459-472.
    12. Boysen, Nils & Emde, Simon, 2016. "The parallel stack loading problem to minimize blockages," European Journal of Operational Research, Elsevier, vol. 249(2), pages 618-627.
    13. Boysen, Nils & Schwerdfeger, Stefan & Stephan, Konrad, 2023. "A review of synchronization problems in parts-to-picker warehouses," European Journal of Operational Research, Elsevier, vol. 307(3), pages 1374-1390.
    14. Dolgui, Alexandre & Kovalev, Sergey & Kovalyov, Mikhail Y. & Nossack, Jenny & Pesch, Erwin, 2014. "Minimizing setup costs in a transfer line design problem with sequential operation processing," International Journal of Production Economics, Elsevier, vol. 151(C), pages 186-194.
    15. Boysen, Nils & Schulze, Philipp & Scholl, Armin, 2022. "Assembly line balancing: What happened in the last fifteen years?," European Journal of Operational Research, Elsevier, vol. 301(3), pages 797-814.
    16. Simon Emde, 2017. "Scheduling the replenishment of just-in-time supermarkets in assembly plants," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 39(1), pages 321-345, January.
    17. Elahi, Mirza M. Lutfe & Rajpurohit, Karthik & Rosenberger, Jay M. & Zaruba, Gergely & Priest, John, 2015. "Optimizing real-time vehicle sequencing of a paint shop conveyor system," Omega, Elsevier, vol. 55(C), pages 61-72.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Boysen, Nils & Fliedner, Malte & Scholl, Armin, 2009. "Sequencing mixed-model assembly lines: Survey, classification and model critique," European Journal of Operational Research, Elsevier, vol. 192(2), pages 349-373, January.
    2. Parames Chutima & Sathaporn Olarnviwatchai, 2018. "A multi-objective car sequencing problem on two-sided assembly lines," Journal of Intelligent Manufacturing, Springer, vol. 29(7), pages 1617-1636, October.
    3. Ioanna Makarouni & John Psarras & Eleftherios Siskos, 2015. "Interactive bicriterion decision support for a large scale industrial scheduling system," Annals of Operations Research, Springer, vol. 227(1), pages 45-61, April.
    4. Boysen, Nils & Fliedner, Malte & Scholl, Armin, 2009. "The product rate variation problem and its relevance in real world mixed-model assembly lines," European Journal of Operational Research, Elsevier, vol. 197(2), pages 818-824, September.
    5. Florian Jaehn & Sergey Kovalev & Mikhail Y. Kovalyov & Erwin Pesch, 2014. "Multiproduct batching and scheduling with buffered rework: The case of a car paint shop," Naval Research Logistics (NRL), John Wiley & Sons, vol. 61(6), pages 458-471, September.
    6. Uli Golle & Franz Rothlauf & Nils Boysen, 2015. "Iterative beam search for car sequencing," Annals of Operations Research, Springer, vol. 226(1), pages 239-254, March.
    7. Karim Aroui & Gülgün Alpan & Yannick Frein, 2017. "Minimising work overload in mixed-model assembly lines with different types of operators: a case study from the truck industry," International Journal of Production Research, Taylor & Francis Journals, vol. 55(21), pages 6305-6326, November.
    8. Elahi, Mirza M. Lutfe & Rajpurohit, Karthik & Rosenberger, Jay M. & Zaruba, Gergely & Priest, John, 2015. "Optimizing real-time vehicle sequencing of a paint shop conveyor system," Omega, Elsevier, vol. 55(C), pages 61-72.
    9. Ding, Fong-Yuen & Zhu, Jin & Sun, Hui, 2006. "Comparing two weighted approaches for sequencing mixed-model assembly lines with multiple objectives," International Journal of Production Economics, Elsevier, vol. 102(1), pages 108-131, July.
    10. Ullrich, Christian A., 2013. "Integrated machine scheduling and vehicle routing with time windows," European Journal of Operational Research, Elsevier, vol. 227(1), pages 152-165.
    11. Pontes, Lara & Neves, Carlos & Subramanian, Anand & Battarra, Maria, 2024. "The maximum length car sequencing problem," European Journal of Operational Research, Elsevier, vol. 316(2), pages 707-717.
    12. Yavuz, Mesut & Tufekci, Suleyman, 2006. "A bounded dynamic programming solution to the batching problem in mixed-model just-in-time manufacturing systems," International Journal of Production Economics, Elsevier, vol. 103(2), pages 841-862, October.
    13. Golle, Uli & Rothlauf, Franz & Boysen, Nils, 2014. "Car sequencing versus mixed-model sequencing: A computational study," European Journal of Operational Research, Elsevier, vol. 237(1), pages 50-61.
    14. Esaignani Selvarajah & Rui Zhang, 2014. "Supply chain scheduling to minimize holding costs with outsourcing," Annals of Operations Research, Springer, vol. 217(1), pages 479-490, June.
    15. Averbakh, Igor, 2010. "On-line integrated production-distribution scheduling problems with capacitated deliveries," European Journal of Operational Research, Elsevier, vol. 200(2), pages 377-384, January.
    16. Iwona Paprocka & Damian Krenczyk, 2023. "On Energy Consumption and Productivity in a Mixed-Model Assembly Line Sequencing Problem," Energies, MDPI, vol. 16(20), pages 1-19, October.
    17. Boysen, Nils & Bock, Stefan, 2011. "Scheduling just-in-time part supply for mixed-model assembly lines," European Journal of Operational Research, Elsevier, vol. 211(1), pages 15-25, May.
    18. Zeynep Ceylan & Hakan Tozan & Serol Bulkan, 2021. "A coordinated scheduling problem for the supply chain in a flexible job shop machine environment," Operational Research, Springer, vol. 21(2), pages 875-900, June.
    19. Andreas Drexl & Alf Kimms, 2001. "Sequencing JIT Mixed-Model Assembly Lines Under Station-Load and Part-Usage Constraints," Management Science, INFORMS, vol. 47(3), pages 480-491, March.
    20. Staeblein, Thomas & Aoki, Katsuki, 2015. "Planning and scheduling in the automotive industry: A comparison of industrial practice at German and Japanese makers," International Journal of Production Economics, Elsevier, vol. 162(C), pages 258-272.

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:ejores:v:216:y:2012:i:3:p:594-604. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/locate/eor .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.