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Designing a mixed-model, open-station assembly line using mixed-integer programming

Author

Listed:
  • B R Sarker

    (Louisiana State University)

  • H Pan

    (A-Plus Manufacturing Corporation)

Abstract

An open-station assembly line that manufactures mixed models of sheet metal cabinets is considered in this research. The problem minimizes the total cost of the idle and utility times incurred in an assembly line with different line parameters (such as launch interval, station length, starting point of work, upstream walk, locus of the operator's movement, etc.) and operation sequences of the mixed models. An open-station system plays a significant controlling role in determining the optimal line parameters that minimize the total cost of idle and utility times in a mixed-model assembly line. Thus, a mixed-integer programming model for an open-station system is developed here to determine line parameters optimally. The model is tested on a three-station mixed-model line, which is a partial representation of a complete long assembly line. This research obtained a set of line parameters that minimize the total cost of idle and utility times optimally. Results indicate that the minimum total cost of idle and utility times in an open-station system decreases with line length. Other results pertinent to the line design are also demonstrated.

Suggested Citation

  • B R Sarker & H Pan, 2001. "Designing a mixed-model, open-station assembly line using mixed-integer programming," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 52(5), pages 545-558, May.
    • Handle: RePEc:pal:jorsoc:v:52:y:2001:i:5:d:10.1057_palgrave.jors.2601118
    DOI: 10.1057/palgrave.jors.2601118
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    Cited by:

    1. Hashemi-Petroodi, S. Ehsan & Thevenin, Simon & Kovalev, Sergey & Dolgui, Alexandre, 2022. "Model-dependent task assignment in multi-manned mixed-model assembly lines with walking workers," Omega, Elsevier, vol. 113(C).
    2. Otto, Alena & Li, Xiyu, 2020. "Product sequencing in multiple-piece-flow assembly lines," Omega, Elsevier, vol. 91(C).
    3. Lopes, Thiago Cantos & Pastre, Giuliano Vidal & Michels, Adalberto Sato & Magatão, Leandro, 2020. "Flexible multi-manned assembly line balancing problem: Model, heuristic procedure, and lower bounds for line length minimization," Omega, Elsevier, vol. 95(C).
    4. 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.
    5. 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.
    6. Morrison, David R. & Sewell, Edward C. & Jacobson, Sheldon H., 2014. "An application of the branch, bound, and remember algorithm to a new simple assembly line balancing dataset," European Journal of Operational Research, Elsevier, vol. 236(2), pages 403-409.

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