Space Assembly Line Balancing Research Articles

A multiobjective model and evolutionary algorithms for robust time and space assembly line balancing under uncertain demand

Changes in demand when manufacturing different products require an optimization model that includes robustness in its definition and methods to deal with it. In this work we propose the r-TSALBP, a multiobjective model for assembly line balancing to search for the most robust line configurations when demand changes. The robust model definition considers a set of demand scenarios and presents temporal and spatial overloads of the stations in the assembly line of the products to be assembled. We present two multiobjective evolutionary algorithms to deal with one of the r-TSALBP variants. The first algorithm uses an additional objective to evaluate the robustness of the solutions. The second algorithm employs a novel adaptive method to evolve separate populations of robust and non-robust solutions during the search. Results show the improvements of using robustness information during the search and the outstanding behavior of the adaptive evolutionary algorithm for solving the problem. Finally, we analyze the managerial impacts of considering the r-TSALBP model for the different organization departments by exploiting the values of the robustness metrics.

A robustness information and visualization model for time and space assembly line balancing under uncertain demand

The time and space assembly line balancing problem (TSALBP) is a realistic multiobjective version of assembly line balancing industrial problems involving the joint optimization of conflicting criteria such as the cycle time, the number of stations, and the area of these stations. However, the existing problem formulation does not consider the industrial scenario where the demand of a set of mixed products is variable and uncertain. In this work we propose to introduce novel robustness functions to measure how robust the line configuration is when the production plans demand changes. These functions are based on the stations overload under future demand conditions and are used as additional a posteriori information for the non-dominated solutions found by any multiobjective optimization method. The values of the robustness functions are put together with a novel graphical representation to form a generic model that aims to offer a better picture of the robustness of the set of Pareto-optimal solutions.Real data from the assembly line and production planning of the Nissan plant of Barcelona is considered for the experimentation. This information is also employed to develop a new TSALBP instance generator (NTIGen) that can generate problem instances having industrial real-like features. The use of the robustness information model is illustrated in an experimentation formed by a set of instances generated by NTIGen. Results show how the use of this robustness information model is necessary for the decision maker as it allows her/him to discriminate between different assembly line configurations when future demand conditions vary.

Multiobjective memetic algorithms for time and space assembly line balancing

This paper presents three proposals of multiobjective memetic algorithms to solve a more realistic extension of a classical industrial problem: time and space assembly line balancing. These three proposals are, respectively, based on evolutionary computation, ant colony optimisation, and greedy randomised search procedure. Different variants of these memetic algorithms have been developed and compared in order to determine the most suitable intensification–diversification trade-off for the memetic search process. Once a preliminary study on nine well-known problem instances is accomplished with a very good performance, the proposed memetic algorithms are applied considering real-world data from a Nissan plant in Barcelona (Spain). Outstanding approximations to the pseudo-optimal non-dominated solution set were achieved for this industrial case study.

An advanced multiobjective genetic algorithm design for the time and space assembly line balancing problem

Time and space assembly line balancing considers realistic multiobjective versions of the classical assembly line balancing industrial problems involving the joint optimization of conflicting criteria such as the cycle time, the number of stations, and/or the area of these stations. In addition to their multi-criteria nature, the different problems included in this field inherit the precedence constraints and the cycle time limitations from assembly line balancing problems, which altogether make them very hard to solve. Therefore, time and space assembly line balancing problems have been mainly tackled using multiobjective constructive metaheuristics. Global search algorithms in general – and multiobjective genetic algorithms in particular – have shown to be ineffective to solve them up to now because the existing approaches lack of a proper design taking into account the specific characteristics of this family of problems. The aim of this contribution is to demonstrate the latter assumption by proposing an advanced multiobjective genetic algorithm design for the 1/3 variant of the time and space assembly line balancing problem which involves the joint minimization of the number and the area of the stations given a fixed cycle time limit. This novel design takes the well known NSGA-II algorithm as a base and considers the use of a new coding scheme and sophisticated problem specific operators to properly deal with the said problematic questions. A detailed experimental study considering 10 different problem instances (including a real-world instance from the Nissan plant in Barcelona, Spain) will show the good yield of the new proposal in comparison with the state-of-the-art methods.

Including different kinds of preferences in a multi-objective ant algorithm for time and space assembly line balancing on different Nissan scenarios

Most of the decision support systems for balancing industrial assembly lines are designed to report a huge number of possible line configurations, according to several criteria. In this contribution, we tackle a more realistic variant of the classical assembly line problem formulation, time and space assembly line balancing. Our goal is to study the influence of incorporating user preferences based on Nissan automotive domain knowledge to guide the multi-objective search process with two different aims. First, to reduce the number of equally preferred assembly line configurations (i.e., solutions in the decision space) according to Nissan plants requirements. Second, to only provide the plant managers with configurations of their contextual interest in the objective space (i.e., solutions within their preferred Pareto front region) based on real-world economical variables. We face the said problem with a multi-objective ant colony optimisation algorithm. Using the real data of the Nissan Pathfinder engine, a solid empirical study is carried out to obtain the most useful solutions for the decision makers in six different Nissan scenarios around the world.

Multiobjective constructive heuristics for the 1/3 variant of the time and space assembly line balancing problem: ACO and random greedy search

In this work we present two new multiobjective proposals based on ant colony optimisation and random greedy search algorithms to solve a more realistic extension of a classical industrial problem: time and space assembly line balancing. Some variants of these algorithms have been compared in order to find out the impact of different design configurations and the use of heuristic information. Good performance is shown after applying every algorithm to 10 well-known problem instances in comparison to NSGA-II. In addition, those algorithms which have provided the best results have been employed to tackle a real-world problem at the Nissan plant, located in Spain.

A new diversity induction mechanism for a multi-objective ant colony algorithm to solve a real-world time and space assembly line balancing problem

Time and space assembly line balancing consid- ers realistic multi-objective versions of the classical assem- bly line balancing industrial problems. It involves the joint optimisation of conflicting criteria such as the cycle time, the number of stations, and/or the area of these stations. The different problems included in this area also inherit the precedence constraints and the cycle time limitations from assembly line balancing problems. The presence of these hard constraints and their multi-criteria nature make these problems very hard to solve. Multi-objective construc- tive metaheuristics (in particular, multi-objective ant colony optimisation) have demonstrated to be suitable approaches to solve time and space assembly line balancing problems. The aim of this contribution is to present a new mechanism to induce diversity in an existing multi-objective ant col- ony optimisation algorithm for the 1/3 variant of the time and space assembly line balancing problem. This variant is quite realistic in the automative industry as it involves the joint minimisation of the number and the area of the stations