Optimizing Mixed-Model Synchronous Assembly Lines with Bipartite Sequence-Dependent Setup Times in Advanced Manufacturing

Asieh Varyani, Mohsen Salehi and Meysam Heydari Gharahcheshmeh ()
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Asieh Varyani: Department of Mechanical, Industrial, and Manufacturing Engineering, Oregon State University, SW Monroe Avenue, Corvallis, OR 97331, USA
Mohsen Salehi: Department of Industrial Engineering, Faculty of Engineering, Bu-Ali Sina University, Hamedan 6517838623, Iran
Meysam Heydari Gharahcheshmeh: Department of Mechanical Engineering, San Diego State University, 5500 Campanile Drive, San Diego, CA 92182, USA

Energies, 2024, vol. 17, issue 12, 1-19

Abstract: In advanced manufacturing, optimizing mixed-model synchronous assembly lines (MMALs) is crucial for enhancing productivity and adhering to sustainability principles, particularly in terms of energy consumption and energy-efficient sequencing. This paper introduces a novel approach by categorizing sequence-dependent setup times into bipartite categories: workpiece-independent and workpiece-dependent. This strategic division streamlines assembly processes, reduces idle times, and decreases energy consumption through more efficient machine usage. A new mathematical model is proposed to minimize the intervals at which workpieces are launched on an MMAL, aiming to reduce operational downtime that typically leads to excessive energy use. Given the Non-deterministic Polynomial-time hard (NP-hard) nature of this problem, a genetic algorithm (GA) is developed to efficiently find solutions, with performance compared against the traditional branch and bound technique (B&B). This method enhances the responsiveness of MMALs to variable production demands and contributes to energy conservation by optimizing the sequence of operations to align with energy-saving objectives. Computational experiments conducted on small and large-sized problems demonstrate that the proposed GA outperforms the conventional B&B method regarding solution quality, diversity level, and computational time, leading to energy reductions and enhanced cost-effectiveness in manufacturing settings.

Keywords: energy consumption; energy-efficient sequencing; manufacturing; mixed-model synchronous assembly line; cycle times (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2024
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