Abstract
This article presents a novel approach for the automated 3D-layout planning of multi-station assembly lines. The planning method is based on a comprehensive model of the used production resources, including their geometry, kinematic properties, and general characteristics. Different resource types can be included in the planning system. A genetic algorithm generates and optimizes possible layouts for a line. The optimization aims to minimize the line’s area and the costs for assembling the line while simultaneously optimizing the resources’ positioning to perform their tasks. The line’s cycle time is considered as a boundary condition. For the evaluation of different layout alternatives, a multi-body simulation is performed. A parameter study is used to set the algorithm’s parameters. Afterward, the algorithm is applied to three increasingly complex examples to validate and evaluate its functionality. The approach is promising for industrial applications as it allows the integration of various resource types and individualization of the optimization function.
Highlights
Today automated assembly lines are commonly used to manufacture products
The ideal layout is highly dependent on the used resources and their characteristics, especially if they need to access the assembled product to perform their task
We present a solution approach for layout planning of multi-station assembly lines
Summary
Today automated assembly lines are commonly used to manufacture products. The spatial positioning of production resources has a crucial influence on the planned system’s quality and is a significant step in designing a new line (Bullinger, 1986). The ideal layout is highly dependent on the used resources and their characteristics (like kinematics), especially if they need to access the assembled product to perform their task. An assembly station might contain multiple robots that have to access the product sequentially and a camera to visually monitor the performed processes simultaneously. Another challenging factor is the flow of material and the transport of the product from one station to the end which needs to be ensured. Arranging the resources is a time-consuming process, whose automation offers the potential to decrease the neces-
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