Automatic configuration of a powertrain assembly line layout based on a KBE approach

The design and the configuration of manufacturing systems, such as assembly lines layouts, are time consuming activities, mainly based on implicit knowledge and no definite rules. This complicated design process is associated with high costs, long lead times and high probability of risks and reworks. Knowledge Based Engineering (KBE) is a technique that can tackle these issues and support the engineers in the early design steps of a manufacturing system with a comprehensive and systematic approach, into the integrated design in a complex system and its related processes. The purpose of this research involve the use of KBE methodology in order to collect and formalize knowledge about the a case study, the design of an assembly line layout system for the cylinder head valve of a car engine. With the formalization of the case study is possible to create an application of configuration that supports the decision making process during the preliminary design phase. The possibility to extend the process to a multi objective optimization is considered. The methodology should be able to help manufacturing equipment providers to shrink design times, evaluating more alternatives and integrating different activities related to the preliminary design phase of a system. This research proposes a practical approach combining the current research state of the art and a real industrial environment for knowledge extraction and application.

Multi-objective Early-stage Design of Automotive Hybrid Assembly Lines

This article presents a novel approach for the automated design of assembly lines that combines the assembly line balancing problem with resource selection and the positioning of the chosen resources into one single optimisation problem. Existing approaches for the automated planning of assembly plants either focus on one planning step or work through different planning steps sequentially. So far, no method exists that sufficiently takes into account the interdependency between the selection and positioning of resources. This article addresses this problem by presenting a bi-level optimisation approach for the automated design of assembly lines. A nested genetic algorithm is used to solve an assembly line balancing problem that includes the selection of production resources while simultaneously considering the layouting options for the chosen resources. Three examples for the evaluation and validation of the algorithm are presented. The presented approach is economically promising as the design of assembly lines requires a lot of expert knowledge and is still mostly done manually.

Assembly lines with fractional tasks increase the throughput with a better workload balancing among the stations. The possibility to share tasks between two consecutive stations can also support the design of assembly lines with redundancies of the tasks. The redundancy of the tasks allows reacting to short failures or variations in processing time. This paper proposes a framework to support the design and control of redundancy assembly lines. The first problem concerns a modified mixed-integer linear programming model used for the fractional allocation assembly line problem to design redundancy assembly lines. Then, this research proposes control policies to manage the allocation of the tasks shared between two consecutive stations. Finally, the simulation evaluates the performance of the proposed methods to handle short failures and uncertain processing times. The numerical results show the potential improvements of the proposed methods with a limited number of redundancies. The main improvements concern the reduction of throughput time and work in process.

Purpose – This study seeks to present a simple assembly line design and its balance for a low‐volume manufacturing company.Design/methodology/approach – The study presents experiences with the design and implementation of a simple assembly line. The implementation concerns three aspects; design and construction of the assembly line, the assembly analysis of the product, and then balancing of the line. It also discusses construction and implementation difficulties of this tactical tool in the case company.Findings – The study presents some outcomes from the design, implementation, and balancing of an assembly line for SMEs.Research limitations/implications – The study is limited by the case company and its experience.Practical implications – This study is not pure theoretical study, it has application stages for industry, and it provides some real interface for the people from SMEs.Originality/value – The approach has an original value in respect of implementation of assembly line for a small manufacturing...

PurposeCycle time fluctuations in assembly lines are one of the important reasons of re‐balancing. As a result of re‐balancing of assembly lines, it will be necessary to change task sequences or equipment locations. The purpose of this paper is to find the task sequence which enables assembly line balancing (ALB) with minimum number of stations (NS) for different cycle times such that tasks and equipment or fixture locations remain unchanged.Design/methodology/approachIn this paper a heuristic which consist of two stages is proposed to find a common task sequence for different cycle times in assembly lines.FindingsIt is shown that optimal NS for different cycle times can be achieved with a fixed task sequence.Research limitations/implicationsThe approach is limited to a single model case. Model variety together with cycle time variety can be investigated in further studies.Practical implicationsAssembly lines which require less time and cost for re‐balancing can be easily designed by the proposed approach.Originality/valueALB problem is handled with a new viewpoint. Also, it is observed that the proposed approach serves as a bridge between assembly line design and balancing. In this regard, it is thought to have an important place in the ALB literature.

The total cost of assembly is a critical factor in robotic assembly line balancing, as it encompasses all the costs associated with the assembly line, including initial costs, setup, maintenance, and energy cost. This study introduces a different approach to the robotic assembly line balancing problem, with a dual focus on minimizing both cycle time and overall assembly costs. The effectiveness of the proposed approach is validated through three case study problems taken from the literature and results are compared to traditional assembly allocation methods. For case study 1, 89.4% (42 out of 47) of the solutions achieved a lower total cost, and 34% (16 out of 47) of the solutions utilized fewer workstations; and for case study 2, 96.4% (108 out of 112) of the solutions achieved a lower total cost, and 58.9% (66 out of 112) of the solutions utilized fewer workstations for the same cycle time. These results demonstrate a significant savings in cost and a notable improvement in workstation efficiency for a substantial portion of the solutions. This comprehensive approach allows an effective resource allocation, reduces inefficiencies, and enhances the overall cost-effectiveness and performance of the robotic assembly line. It also supports decision-makers in selecting more sustainable and economically viable assembly line solutions that optimize both productivity and energy efficiency.

AutomationML as Seamless Data Exchange Format for Integration of Automated Planning Tools for Assembly Line Design

Clustering of geometric objects is a very familiar and important problem in many different areas of applications as well as in the theoretical foundation of some modern fields of computer science. This paper describes how design problems, especially the design of an assembly line, can be transformed into a clustering problem. In order to solve the problem for large sizes of input data we introduce a structure, called Voronoi Tree, which applied to our real world data (assembly line design) did not only reduce the time to get a feasible design of an assembly line dramatically, but additionally increased the value of the design by more than 30% (in comparison with standard design methods). In addition to this we introduce a clustering method which is of interest for those applications which can be transformed to planar clustering problems. In this particular case it is possible to compute an (hierarchically) optimized clustering with resp. to a large class of clustering measures in timeO(nn1/2log3n+UF(n)nn1/2+PF(n)) [n: number of points;UF(n), PF(n) dependent on the chosen clustering measure].

A Simulation Study on the Layout Design of Micro Assembly Line for Lens Module

Automated design of multi-station assembly lines

The purpose of this paper is to describe some of the main problems concerning assembly line design. The focus will be on the following steps: (1) the input data preparation, (2) the elaboration of the logical layout of the line, which consists in the distribution of operations among stations along the line and an assignment of resources to the different stations, (3) finally the mapping phase using a simulation package to check the obtained results. This work presents a new method to tackle the hybrid assembly line design, dealing with multiple objectives. The goal is to minimize the total cost of the line by integrating design (station space, cost, etc.) and operation issues (cycle time, precedence constraints, availability, etc.). This paper also presents in detail a very promising approach to solve multiple objective problems. It is a multiple objective grouping genetic algorithm hybridized with the multicriteria decision-aid method PROMETHEE II. An approach to deal with user's preferences in design problems is also introduced. The essential concepts adopted by the method are described and its application to an industrial case study is presented.

The most important factor affecting efficiency and ergonomic risk levels in an assembly line design is the problem of assigning certain tasks to certain stations, namely the assembly line balancing problem. In the literature, assembly line balancing problem has often been studied, but studies that consider ergonomic risks are deficient. Recently, it has been one of the issues that have started to attract great attention with the realization of health problems caused by assembly lines. To this end, in this study, a bi‐objective mathematical model is developed that considers balancing assembly line station time and ergonomic risk levels, simultaneously. It is aimed to minimize both station time and the total deviations of ergonomic risk scores for the stations. Weighted sum and conic scalarization methods are applied to solve the bi‐objective model. To analyze the outcomes of the developed model, an application is proposed and tested on a real industrial case, at a home appliance assembly line. The deployment of the OMAX method is a contribution to the literature since it shows an analysis tool which evaluates the results of assembly line balancing. This method evaluates the performance of the stations based on different criteria such as station time and ergonomic risk. The number of high‐risk stations is obtained as 13 in the single‐objective model aiming to minimize the station time, while it is found to be nine in the bi‐objective model solved with CSM, without an increase in the total number of stations.

Traditionally assembly line balancing problems have been examined under the assumption of serial work station design. Thus no pair of work stations could be simultaneously working on the same copy of a product. This paper presents two models for which this assumption is dropped. The algorithms developed for operational design of such assembly lines are presented along with sample problems to demonstrate the computational procedures and advantages of these models.

Recently, the competitive environment is very tough in shipbuilding industry and under these circumstances, manufacturing a ship in a shorter time becomes significantly important in order to meet the customer demands. Therefore, it is hard to do that by using traditional manufacturing techniques. The shipyards located in Turkey usually have functional locations for the machines and this situation often causes longer production times. Instead of this, assembly lines should be redesigned as workshops in the shipyard. Prefabrication work unit is a good example in which an assembly line is needed to be designed. In this study, an assembly line design for prefabrication work unit was performed. For this, assignments of work operations to work shops were carried out by using Largest Set Rule Algorithm and some alternatives were created according to compare the different values of cycle time. These alternatives were simulated by using a production simulation program and the most appropriate assembly line design was presented.