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Sequencing to Minimize Work Overload in Assembly Lines with Product Options

Author

Listed:
  • Candace Arai Yano

    (Department of Industrial and Operations Engineering, University of Michigan, Ann Arbor, Michigan 48109-2117)

  • Ram Rachamadugu

    (School of Business Administration, University of Michigan, Ann Arbor, Michigan 48109)

Abstract

We address the problem of sequencing jobs, each of which is characterized by one of a large number of possible combinations of customer-specified options, on a paced assembly line. These problems arise frequently in the automotive industry. One job must be launched into the system at equal time intervals, where the time interval (or cycle time) is prespecified. The problem is to sequence the jobs to maximize the total amount of work completed, or equivalently, to minimize the total amount of incomplete work (or work overload). Since there is a large number of option combinations, each job is almost unique. This fact precludes the use of existing mixed model assembly line sequencing techniques. We first consider the sequencing problem for a single station which can perform two different sets of operations. We characterize the optimal solution for this problem and use the results as the basis for a heuristic procedure for multiple stations. Computational results with data from a major automobile company are reported.

Suggested Citation

  • Candace Arai Yano & Ram Rachamadugu, 1991. "Sequencing to Minimize Work Overload in Assembly Lines with Product Options," Management Science, INFORMS, vol. 37(5), pages 572-586, May.
  • Handle: RePEc:inm:ormnsc:v:37:y:1991:i:5:p:572-586
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    File URL: http://dx.doi.org/10.1287/mnsc.37.5.572
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    Cited by:

    1. Drexl, Andreas & Jordan, Carsten, 1994. "Materialflußorientierte Produktionssteuerung bei Variantenfließfertigung," Manuskripte aus den Instituten für Betriebswirtschaftslehre der Universität Kiel 362, Christian-Albrechts-Universität zu Kiel, Institut für Betriebswirtschaftslehre.
    2. 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.
    3. Xiaobo, Zhao & Ohno, Katsuhisa, 2000. "Properties of a sequencing problem for a mixed model assembly line with conveyor stoppages," European Journal of Operational Research, Elsevier, vol. 124(3), pages 560-570, August.
    4. Marshall L. Fisher & Christopher D. Ittner, 1999. "The Impact of Product Variety on Automobile Assembly Operations: Empirical Evidence and Simulation Analysis," Management Science, INFORMS, vol. 45(6), pages 771-786, June.
    5. Matthießen, Lars & Drexl, Andreas & Kimms, Alf, 2000. "Constraint propagation algorithms for the car sequencing problem," Manuskripte aus den Instituten für Betriebswirtschaftslehre der Universität Kiel 531, Christian-Albrechts-Universität zu Kiel, Institut für Betriebswirtschaftslehre.
    6. Kucukkoc, Ibrahim & Zhang, David Z., 2014. "Mathematical model and agent based solution approach for the simultaneous balancing and sequencing of mixed-model parallel two-sided assembly lines," International Journal of Production Economics, Elsevier, vol. 158(C), pages 314-333.
    7. Bautista, Joaquín & Alfaro, Rocío & Batalla, Cristina, 2015. "Modeling and solving the mixed-model sequencing problem to improve productivity," International Journal of Production Economics, Elsevier, vol. 161(C), pages 83-95.
    8. repec:taf:tprsxx:v:55:y:2017:i:21:p:6305-6326 is not listed on IDEAS
    9. Heike, G. & Ramulu, M. & Sorenson, E. & Shanahan, P. & Moinzadeh, K., 2001. "Mixed model assembly alternatives for low-volume manufacturing: The case of the aerospace industry," International Journal of Production Economics, Elsevier, vol. 72(2), pages 103-120, July.
    10. Jin, Mingzhou & Luo, Yi & Eksioglu, Sandra D., 2008. "Integration of production sequencing and outbound logistics in the automotive industry," International Journal of Production Economics, Elsevier, vol. 113(2), pages 766-774, June.
    11. Jérémie Gallien & Serguei Netessine & Maher Lahmar & Hakan Ergan & Sergei V. Savin & Michael J. Fry, 2001. "The MSOM Society Student Paper Competition: Extended Abstracts of 2000 Winners," Manufacturing & Service Operations Management, INFORMS, vol. 3(1), pages 1-1.
    12. Bautista, J. & Companys, R. & Corominas, A., 1996. "Heuristics and exact algorithms for solving the Monden problem," European Journal of Operational Research, Elsevier, vol. 88(1), pages 101-113, January.
    13. repec:pal:jorsoc:v:60:y:2009:i:3:d:10.1057_palgrave.jors.2602533 is not listed on IDEAS
    14. Kim, Yeo Keun & Kim, Jae Yun & Kim, Yeongho, 2006. "An endosymbiotic evolutionary algorithm for the integration of balancing and sequencing in mixed-model U-lines," European Journal of Operational Research, Elsevier, vol. 168(3), pages 838-852, February.
    15. Lovgren, Robin H. & Racer, Michael J., 2000. "Algorithms for mixed-model sequencing with due date restrictions," European Journal of Operational Research, Elsevier, vol. 120(2), pages 408-422, January.
    16. Korkmazel, Tugrul & Meral, Sedef, 2001. "Bicriteria sequencing methods for the mixed-model assembly line in just-in-time production systems," European Journal of Operational Research, Elsevier, vol. 131(1), pages 188-207, May.
    17. 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.
    18. Drexl, Andreas & Kimms, Alf, 1999. "Belastungsorientierte Just-in-Time Variantenfließfertigung," Manuskripte aus den Instituten für Betriebswirtschaftslehre der Universität Kiel 502, Christian-Albrechts-Universität zu Kiel, Institut für Betriebswirtschaftslehre.
    19. Bautista, Joaquin & Cano, Jaime, 2008. "Minimizing work overload in mixed-model assembly lines," International Journal of Production Economics, Elsevier, vol. 112(1), pages 177-191, March.
    20. Bautista, Joaquín & Cano, Alberto & Alfaro, Rocío, 2012. "Models for MMSP-W considering workstation dependencies: A case study of Nissan’s Barcelona plant," European Journal of Operational Research, Elsevier, vol. 223(3), pages 669-679.
    21. Bautista, Joaquín & Cano, Alberto, 2011. "Solving mixed model sequencing problem in assembly lines with serial workstations with work overload minimisation and interruption rules," European Journal of Operational Research, Elsevier, vol. 210(3), pages 495-513, May.
    22. Drexl, Andreas & Kimms, Alf, 1997. "Sequencing JIT mixed-model assembly lines under station load- and part usage-constraints," Manuskripte aus den Instituten für Betriebswirtschaftslehre der Universität Kiel 460, Christian-Albrechts-Universität zu Kiel, Institut für Betriebswirtschaftslehre.

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