Analysis of buffered assembly line productivity

2014 ◽  
Vol 34 (1) ◽  
pp. 34-40 ◽  
Author(s):  
Ryspek Usubamatov ◽  
Abd Alsalam Alsalameh ◽  
Rosmaini Ahmad ◽  
Abdul Rahman Riza
Keyword(s):  
Mathematical Model ◽  
Assembly Line ◽  
Optimal Number ◽  
Limited Capacity ◽  
Content Type ◽  
Maximum Productivity ◽  
Productivity Rate ◽  
Assembly Technology ◽  
Mathematical Equations ◽  
Initial Results

Purpose – The paper aims to study car assembly line, to show its productivity rate, and to derive a mathematical model for the productivity rate of the assembly line segmented into sections with embedded buffers. Design/methodology/approach – The paper performs productivity calculations based on data obtained from the assembly processes of a car and shows the maximum productivity of the assembly line. The equations of the assembly line productivity, the optimal number of assembly stations, and the necessary number of the assembly line's sections with buffers are derived via the criterion of maximum productivity. Findings – The paper provides the productivity diagram of the assembly line that illustrates various measures of productivity, one that depends on the number of assembly stations, the number of sections in the line, and the capacity of the buffers. The diagram is based on the proposed mathematical equations for the productivity of the assembly line as a function of the assembly technology, number of stations, number of sections, and the capacity of the buffer. Research limitations/implications – Solutions towards increasing the productivity of the assembly line are given based on the results of the study and analysis of the assembly processes in real industrial environments. Practical implications – The paper includes the equation for the productivity of the assembly line, which is segmented into sections with limited capacity of the buffers, thereby enabling the calculation of its maximum productivity and the optimal number of assembly stations. Originality/value – The paper presents an analysis of productivity and a mathematical model for calculating the productivity of the assembly line, which is segmented into sections with embedded buffers of limited capacity. The initial results of the research have been obtained from a real industrial environment.

scholarly journals Engineering Mathematical Analysis Method for Productivity Rate in Linear Arrangement Serial Structure Automated Flow Assembly Line

2015 ◽  
Vol 2015 ◽  
pp. 1-10
Author(s):  
Tan Chan Sin ◽  
Ryspek Usubamatov ◽  
M. A. Fairuz ◽  
Mohd Fidzwan B. Md. Amin Hamzas ◽  
Low Kin Wai
Keyword(s):  
Mathematical Model ◽  
Failure Rate ◽  
Mathematical Analysis ◽  
Assembly Line ◽  
Flow Line ◽  
Analysis Method ◽  
Machining Time ◽  
Linear Arrangement ◽  
Final Assembly ◽  
Productivity Rate

Productivity rate (Q) or production rate is one of the important indicator criteria for industrial engineer to improve the system and finish good output in production or assembly line. Mathematical and statistical analysis method is required to be applied for productivity rate in industry visual overviews of the failure factors and further improvement within the production line especially for automated flow line since it is complicated. Mathematical model of productivity rate in linear arrangement serial structure automated flow line with different failure rate and bottleneck machining time parameters becomes the basic model for this productivity analysis. This paper presents the engineering mathematical analysis method which is applied in an automotive company which possesses automated flow assembly line in final assembly line to produce motorcycle in Malaysia. DCAS engineering and mathematical analysis method that consists of four stages known as data collection, calculation and comparison, analysis, and sustainable improvement is used to analyze productivity in automated flow assembly line based on particular mathematical model. Variety of failure rate that causes loss of productivity and bottleneck machining time is shown specifically in mathematic figure and presents the sustainable solution for productivity improvement for this final assembly automated flow line.

Multi-manned assembly line balancing problem with balanced load density

2015 ◽  
Vol 35 (1) ◽  
pp. 137-142 ◽  
Author(s):  
Hamid Yilmaz ◽  
Mustafa Yilmaz
Keyword(s):  
Mathematical Model ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Assembly Lines ◽  
Content Type ◽  
Task Load ◽  
Balance Task ◽  
Assembly Line Balancing Problem ◽  
First Time

Purpose – The purpose of this paper is balancing multi-manned assembly lines with load-balancing constraints in addition to conventional ones Most research works about the multi-manned assembly line balancing problems are focused on the conventional industrial measures that minimize total number of workers, number of multi-manned workstations or both. Design/methodology/approach – This paper provides a remedial constraint for the model to balance task load density for each worker in workstations. Findings – Comparisons between the proposed mathematical model and the existing multi-manned mathematical model show a quite promising better task load density performance for the proposed approach. Originality/value – In this paper, a mathematical model that combines the minimization of multi-manned stations, worker numbers and difference of task load density of workers is proposed for the first time.

Simple assembly line balancing problem of Type 1 with grey demand and grey task durations

2019 ◽  
Vol 9 (4) ◽  
pp. 401-414 ◽  
Author(s):  
Oğuzhan Ahmet Arık ◽  
Erkan Köse ◽  
Jeffrey Forrest
Keyword(s):  
Mathematical Model ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Grey Theory ◽  
Content Type ◽  
Task Durations ◽  
Simple Assembly ◽  
And Task

Purpose The purpose of this paper is to present a mixed integer programming model for simple assembly line balancing problems (SALBP) with Type 1 when the annual demand and task durations are uncertain and encoded with grey numbers. Design/methodology/approach Grey theory and grey numbers are used for illustrating the uncertainty of parameters in an SALBP, where the objective is to minimize the total number of workstations. The paper proposes a 0-1 mathematical model for SALBP of Type 1 with grey demand and grey task durations. Findings The uncertainty of the demand and task durations are encoded with grey numbers and a well-known 0-1 mathematical model for SALBP of Type 1 is modified to find the minimum number of workstations in order to meet both the lower and upper bounds of the uncertain demand. The results obtained from the proposed mathematical model show a task-workstation assignment that does not distribute precedence relations among tasks and workstations and the sum of task durations in each single workstation is less than or equal to the grey cycle time. Originality/value The grey theory and grey numbers have not been previously used to identify uncertainties in assembly line balancing problems. Therefore, this study provides an important contribution to the literature.

An improved flower pollination algorithm for solving a Type-II U-shaped assembly line balancing problem with energy consideration

2020 ◽  
Vol 40 (6) ◽  
pp. 847-856
Author(s):  
Beikun Zhang ◽  
Liyun Xu
Keyword(s):  
Mathematical Model ◽  
Energy Consumption ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Flower Pollination Algorithm ◽  
Discrete Problem ◽  
Content Type ◽  
Flower Pollination ◽  
Assembly Line Balancing Problem

Purpose The increasing energy shortage leads to worldwide attentions. This paper aims to develop a mathematical model and optimization algorithm to solve the energy-oriented U-shaped assembly line balancing problem. Different from most existing works, the energy consumption is set as a major objective. Design/methodology/approach An improved flower pollination algorithm (IFPA) is designed to solve the problem. The random key encoding mechanism is used to map the continuous algorithm into discrete problem. The pollination rules are modified to enhance the information exchange between individuals. Variable neighborhood search (VNS) is used to improve the algorithm performance. Findings The experimental results show that the two objectives are in conflict with each other. The proposed methodology can help manager obtain the counterbalance between them, for the larger size balancing problems, and the reduction in objectives is even more significant. Besides, the experiment results also show the high efficiency of the proposed IFPA and VNS. Originality/value The main contributions of this work are twofold. First, a mathematical model for the U-shaped assembly line balancing problem is developed and the model is dual foci including minimized SI and energy consumption. Second, an IFPA is proposed to solve the problem.

scholarly journals Re-balancing problem for assembly lines: new mathematical model and exact solution method

2015 ◽  
Vol 35 (1) ◽  
pp. 16-21 ◽  
Author(s):  
Fatme Makssoud ◽  
Olga Battaïa ◽  
Alexandre Dolgui ◽  
Khumbulani Mpofu ◽  
Olayinka Olabanji
Keyword(s):  
Mathematical Model ◽  
Exact Solution ◽  
Design Methodology ◽  
Assembly Line ◽  
Solution Method ◽  
Assembly Lines ◽  
New Production ◽  
Content Type ◽  
Proposed Model ◽  
Initial Line

Purpose – The purpose of this study is to develop a new mathematical model and an exact solution method for an assembly line rebalancing problem. When an existing assembly line has to be adapted to a new production context, the line balancing, resources allocation and component management solutions have to be revised. The objective is to minimize the number of modifications to be done in the initial line in order to reduce the time and investment needed to meet new production requirements. The proposed model is evaluated via a computational experiment. The obtained results the efficacy of the proposed method. Design/methodology/approach – This paper develops a new mathematical model and an exact solution method for an assembly line rebalancing problem with the objective to minimize the number of modifications to be done in the initial line to reduce the time and investments needed to meet new production requirements. Findings – The computational experiments show the efficacy of the proposed method. Originality/value – These reconfiguration costs were analysed for different part-feeding policies that can be adopted in an assembly line.

Human skill integrated motion planning of assembly manipulation for 6R industrial robot

2019 ◽  
Vol 46 (1) ◽  
pp. 171-180
Author(s):  
Yi Liu ◽  
Ming Cong ◽  
Hang Dong ◽  
Dong Liu
Keyword(s):  
Deep Learning ◽  
Motion Planning ◽  
Industrial Robot ◽  
Robotic Assembly ◽  
3D Vision ◽  
Content Type ◽  
Human Skill ◽  
Depth Images ◽  
Positioning Method ◽  
Assembly Technology

Purpose The purpose of this paper is to propose a new method based on three-dimensional (3D) vision technologies and human skill integrated deep learning to solve assembly positioning task such as peg-in-hole. Design/methodology/approach Hybrid camera configuration was used to provide the global and local views. Eye-in-hand mode guided the peg to be in contact with the hole plate using 3D vision in global view. When the peg was in contact with the workpiece surface, eye-to-hand mode provided the local view to accomplish peg-hole positioning based on trained CNN. Findings The results of assembly positioning experiments proved that the proposed method successfully distinguished the target hole from the other same size holes according to the CNN. The robot planned the motion according to the depth images and human skill guide line. The final positioning precision was good enough for the robot to carry out force controlled assembly. Practical implications The developed framework can have an important impact on robotic assembly positioning process, which combine with the existing force-guidance assembly technology as to build a whole set of autonomous assembly technology. Originality/value This paper proposed a new approach to the robotic assembly positioning based on 3D visual technologies and human skill integrated deep learning. Dual cameras swapping mode was used to provide visual feedback for the entire assembly motion planning process. The proposed workpiece positioning method provided an effective disturbance rejection, autonomous motion planning and increased overall performance with depth images feedback. The proposed peg-hole positioning method with human skill integrated provided the capability of target perceptual aliasing avoiding and successive motion decision for the robotic assembly manipulation.

A multi-manned assembly line balancing problem with classified teams: a new approach

2016 ◽  
Vol 36 (1) ◽  
pp. 51-59 ◽  
Author(s):  
Hamid Yilmaz ◽  
Mustafa Yilmaz
Keyword(s):  
Design Methodology ◽  
Assembly Line ◽  
Assembly Line Balancing ◽  
Line Balancing ◽  
Test Problems ◽  
New Approach ◽  
Content Type ◽  
Line Test ◽  
Assembly Line Balancing Problem ◽  
First Time

Purpose – Within team-oriented approaches, tasks are assigned to teams before being assigned to workstations as a reality of industry. So it becomes clear, which workers assemble which tasks. Design/methodology/approach – Team numbers of the assembly line can increase with the number of tasks, but at the same time, due to physical situations of the stations, there will be limitations of maximum working team numbers in a station. For this purpose, heuristic assembly line balancing (ALB) procedure is used and mathematical model is developed for the problem. Findings – Well-known assembly line test problems widely used in the literature are solved to indicate the effectiveness and applicability of the proposed approach in practice. Originality/value – This paper draws attention to ALB problem in which workers have been assigned to teams in advance due to the need for specialized skills or equipment on the line for the first time.

Fractional order generalized thermoelastic response in a half space due to a periodically varying heat source

2018 ◽  
Vol 14 (1) ◽  
pp. 2-15 ◽  
Author(s):  
Jitesh Tripathi ◽  
Shrikant Warbhe ◽  
K.C. Deshmukh ◽  
Jyoti Verma
Keyword(s):  
Mathematical Model ◽  
Heat Source ◽  
Laplace Transform ◽  
Half Space ◽  
Fractional Order ◽  
Order Parameter ◽  
Order Theory ◽  
Numerical Inversion ◽  
Content Type ◽  
Copper Material

Purpose The present work is concerned with the solution of a fractional-order thermoelastic problem of a two-dimensional infinite half space under axisymmetric distributions in which lower surface is traction free and subjected to a periodically varying heat source. The thermoelastic displacement, stresses and temperature are determined within the context of fractional-order thermoelastic theory. To observe the variations of displacement, temperature and stress inside the half space, the authors compute the numerical values of the field variables for copper material by utilizing Gaver-Stehfast algorithm for numerical inversion of Laplace transform. The effects of fractional-order parameter on the variations of field variables inside the medium are analyzed graphically. The paper aims to discuss these issues. Design/methodology/approach Integral transform technique and Gaver-Stehfast algorithm are applied to prepare the mathematical model by considering the periodically varying heat source in cylindrical co-ordinates. Findings This paper studies a problem on thermoelastic interactions in an isotropic and homogeneous elastic medium under fractional-order theory of thermoelasticity proposed by Sherief (Ezzat and El-Karamany, 2011b). The analytic solutions are found in Laplace transform domain. Gaver-Stehfast algorithm (Ezzat and El-Karamany, 2011d; Ezzat, 2012; Ezzat, El Karamany, Ezzat, 2012) is used for numerical inversion of the Laplace transform. All the integrals were evaluated using Romberg’s integration technique (El-Karamany et al., 2011) with variable step size. A mathematical model is prepared for copper material and the results are presented graphically with the discussion on the effects of fractional-order parameter. Research limitations/implications Constructed purely on theoretical mathematical model by considering different parameters and the functions. Practical implications The system of equations in this paper may prove to be useful in studying the thermal characteristics of various bodies in real-life engineering problems by considering the time fractional derivative in the field equations. Originality/value In this problem, the authors have used the time fractional-order theory of thermoelasticity to solve the problem for a half space with a periodically varying heat source to control the speed of wave propagation in terms of heat and elastic waves for different conductivity like weak conductivity, moderate conductivity and super conductivity which is a new and novel contribution.

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