Profit-oriented partial disassembly line design: dealing with hazardous parts and task processing times uncertainty

Multi-objective partial parallel disassembly line balancing problem using hybrid group neighbourhood search algorithm

Increasing environmental awareness in today's society and stricter environmental regulations have forced manufacturing firms to take necessary actions for the recovery of end-of-life (EOL) products through different options (e.g., recycling, remanufacturing,). Disassembly is regarded as a critical operation in EOL treatment of used products since all product recovery options require the disassembly of EOL products at certain levels. This critical operation is generally carried out by forming disassembly lines in product recovery facilities. Miscellaneous methodologies based on heuristics, metaheuristics and mathematical programming have been proposed for the balancing of disassembly lines. Majority of those methodologies assume that disassembly line parameters are deterministic by ignoring the fact that a disassembly line involves great deal of uncertainty mainly due to uncertain conditions of arriving EOL products. Considering this high level of uncertainty, simulation modeling can be an effective tool for the modeling of disassembly lines. In this study, a simulation-based disassembly line balancing methodology is proposed for the explicit consideration of stochastic parameters. First, simulation model of a disassembly line is constructed. Since the disassembly line balancing problem has a combinatorial nature, two commonly used metaheuristics (i.e., genetic algorithms (GAs) and simulated annealing (SA)) are integrated with the simulation model in order to balance the disassembly line. The disassembly sequence and task assignments proposed by GA are compared with the sequence and task assignments proposed by SA. This comparison indicates that GA outperforms SA in four of eight performance measures while both algorithms have the same value for line efficiency measure.

Enumerations and stability analysis of feasible and optimal line balances for simple assembly lines

PurposeThe main objective of this paper is to integrate quality with triple bottom line dimensions as well as economic, social and environmental concerns within a disassembly line balancing problem.Design/methodology/approachThis study presents a new disassembly line balancing model to maintain the triple bottom line. This proposed model applies a hybrid MCDM considering social, environmental, quantitative and qualitative business and quality dimensions. In this research, fuzzy AHP prioritizes the dimensions and fuzzy TOPSIS ranks the disassembly operations.FindingsThe findings show that the disassembly line’s cycle time decreased from 36 s to 32 s, with the main and sub-criteria considered. Therefore, this study reveals that integrating sustainability dimensions with quality may not result in sacrificing cycle time.Originality/valueGlobalization, the increase in demand, the complexity of supply chains and the environmental, economic and social dimensions should be examined together for these operations to be sustainable. Not only these dimensions but also the perception of quality, an essential aspect of production, must be reflected in the disassembly line balancing. There is a need for sustainability issues in disassembly line balancing, which is becoming increasingly important due to environmental concerns, resource conservation, corporate social responsibility and potential cost savings. However, a significant gap in the literature points to the need to cover all three dimensions of the triple bottom line and other production-related dimensions in the disassembly line balancing problem.

ABSTRACTIn the context of Industry 4.0, a production line must be flexible and adaptable to stochastic or real‐world environments. As a result, the assembly line balancing (ALB) problem involves managing uncertainty or stochasticity. Several methods have been proposed, including stochastic mathematical programming models and simulations. However, programming models can only incorporate a few sources of uncertainty that result in impractical or unfeasible solutions to implement due to overlooked complexities, while simulation is only used to test solutions from deterministic approaches or adjust parameters without maintaining their optimum value. The proposed methodology uses a deterministic mathematical model to minimize the cycle time, followed by the simulation to measure the impact of selected sources of uncertainty on the cycle time. Finally, the optimum value of the stochastic parameters is computed using simulation‐based optimization to maintain the average cycle time close to the deterministic one. A real‐life assembly line balancing problem for a motorcycle manufacturing company is solved to test the proposed methodology. The sources of uncertainty are the tasks' stochastic processing times, inter‐arrival time, the number of workers in each station, and the speed of the material handling system. Results show that the average cycle time is above 2.7% from the deterministic value computed by the programming model when the inter‐arrival time is set to 270 60 s; the processing times are allowed to increase or decrease by 3 s; the material handling system's speed is 1.5 m/s; and the number of workers in cells is between 4 and 6, with a speed of 2 m/s. The reader can download the source code and the simulation model to apply the methodology to other instances.

Disassembly operations are inevitable elements of product recovery with the disassembly line as the best choice to carry out the same. The product recovery operations are fully based on disassembly line balancing and because of this, disassembly lines have become the chaise of automated disassembly of returned product. It is difficult to find the optimal balance of a disassembly line because of its N-P hard nature. In this paper a new heuristic is proposed to assign the parts to the disassembly workstations under AND/OR precedence constraints. The heuristic solutions are known as intrinsically optimal/suboptimal solutions of the N-P hard problems. The solution obtained by proposed heuristic has been compared with other heuristic solutions. The heuristic tries to minimize the number of workstations and the cycle time of the line while addressing the different criteria. The methodology of the proposed heuristics has been illustrated with the help of examples and it has been observed that the heuristic generates significantly better result.

Disassembly operations are inevitable elements of product recovery with the disassembly line as the best choice to carry out the same. In the light of different structures of returned products (models) and variations in task completion times, the process of disassembly could not be efficiently mapped on a simple straight line. Another important issue that needs consideration is the task-time variability pertaining to human factor. In order to resolve these complexities a Mixed-Model U-shaped Disassembly Line with Stochastic Task Times has been proposed in this article. A novel approach, Collaborative Ant Colony Optimization (CACO), has been utilized that simultaneously tackles the interrelated problem of line balancing and model sequencing. The distinguishing feature of the proposed approach is that it maintains bilateral colonies of ants which independently identifies the two sequences, but utilizes the information obtained by their collaboration to guide the future path. The approach is tested on benchmark instances that were generated using Design of Experiment techniques and Analysis of Variance is performed to determine the impact of various factors on the objective. The robustness of proposed algorithm is authenticated against Ant Colony Optimization over which it always demonstrated better results thereby proving its superiority on the concerned problem.

The disassembly line is the best choice for automated disassembly of disposal products. Therefore, disassembly line should be designed and balanced so that it can work as efficiently as possible. In this paper, a mathematical model for the multi-objective disassembly line balancing problem is formalized firstly. Then, a novel multi-objective ant colony optimization (MOACO) algorithm is proposed for solving this multi-objective optimization problem. Taking into account the problem constraints, a solution construction mechanism based on the method of tasks assignment is utilized in the algorithm. Additionally, niche technology is used to embed in the updating operation to search the Pareto optimal solutions. Moreover, in order to find the Pareto optimal set, the MOACO algorithm uses the concept of Pareto dominance to dynamically filter the obtained non-dominated solution set. To validate the performance of algorithm, the proposed algorithm is measured over published results obtained from single-objective optimization approaches and compared with multi-objective ACO algorithm based on uniform design. The experimental results show that the proposed MOACO is well suited to multi-objective optimization in disassembly line balancing.

Human-robot collaborative disassembly lines are widely used by remanufacturing companies to disassemble end-of-life (EOL) products. When disassembling large-sized EOL products, each workstation on a disassembly line is generally divided into multiple operating positions, so that different operators can disassemble the same product at their respective positions at the same time, thereby greatly improving efficiency. This paper focuses on a position-constrained human-robot collaborative disassembly planning (PC-HRCDP) problem for the above-mentioned lines, including three subproblems of disassembly sequence planning, disassembly line balancing and robot path planning. A multi-objective mixed integer programming model for PC-HRCDP is developed to solve small-scale instances. Furthermore, a multi-objective multi-fidelity optimisation (MO-MFO) algorithm is proposed to solve large-scale instances. Comprehensive experiments are conducted based on 10 problem instances generated in this study. Experimental results show that the proposed MO-MFO is better than a high-fidelity optimisation algorithm in terms of running time. In addition, benefiting from the strategy of MO-MFO to allocate the limited high-fidelity computational budget to solutions in the two stages of multi-objective optimisation and optimal sampling, MO-MFO is significantly better than the existing representative multi-fidelity optimisation algorithms in terms of the hyper-volume and the inverted generational distance.

With the advancement of science and technology in recent years, the rate of product upgrading by end users has increased, resulting in a high number of End-Of-Life (EOL) products. For environmental protection and economic benefits, disassembly lines are set up to recycle them. A disassembly line balancing problem arises and has attracted widespread attention. In this paper, we design a model to address a class of disassembly line balancing problems in which the main optimization objective is to maximize profits, while keeping carbon emission in a tolerable range. A discrete whale optimization algorithm is proposed to search their high-quality solutions. Its efficiency is verified by comparing its solutions with their analytic solutions obtained from a commercial optimization solver and other swarm intelligence algorithms. Experimental results show that it is significantly faster than CPLEX and other swarm intelligence algorithms in solving large-scale optimization problems while guaranteeing its solutions quality.

Robots are now widely used in product disassembly lines, which significantly improves end-of-life (EOL) product disassembly efficiency. Most of the current research on disassembly line balancing problems focuses on decomposing one product. More than one product can be disassembled concurrently, which can further improve the efficiency. Moreover, uncertainty such as the depreciation of EOL products, may result in disassembly failure. In this research, a stochastic multi-product robotic disassembly line balancing model is established using an AND/OR graph. It takes the precedence relationship, cycle constraint, and disassembly failure into consideration to maximize the profit and minimize the energy consumption for disassembling multiple products. A Pareto-improved multi-objective brainstorming optimization algorithm combined with stochastic simulation is proposed to solve the problem. Furthermore, by conducting experiments on some real cases and comparing with four state-of-the-art multi-objective optimization algorithms, i.e., the multi-objective discrete gray wolf optimizer, artificial bee colony algorithm, nondominated sorting genetic algorithm II, and multi-objective evolutionary algorithm based on decomposition, this paper validates its excellent performance in solving the concerned problem.

A Piecewise Linear Model for Stochastic Disassembly Line Balancing

PurposeThis paper considers the assembly line worker assignment and balancing problem of type-2 (ALWABP-2) with fuzzy task times. This problem is an extension of the (simple) SALBP-2 in which task times are worker-dependent and concurrently uncertain. Two criteria are simultaneously considered for minimization, namely, fuzzy cycle time and fuzzy smoothness index.Design/methodology/approachFirst, we show how fuzzy concepts can be used for managing uncertain task times. Then, we present a multiobjective genetic algorithm (MOGA) to solve the problem. MOGA is devoted to the search for Pareto-optimal solutions. For facilitating effective trade-off decision-making, two different MO approaches are implemented and tested within MOGA: a weighted-sum based approach and a Pareto-based approach.FindingsExperiments over a set of fuzzified test problems show the effect of these approaches on the performance of MOGA while verifying its efficiency in terms of both solution and time quality.Originality/valueTo the author’s knowledge, no previous published work in the literature has studied the biobjective assembly line worker assignment and balancing problem of type-2 (ALWABP-2) with fuzzy task times.

One of the simple assembly line balancing problems (SALBPs), known as SALBP-E, is considered. It consists in assigning a given set V={1,2,…,n} of elementary tasks to linearly ordered workstations with respect to precedence and capacity restrictions while minimizing the following product: number of used workstations × working time on the most loaded one. The stability of feasible and optimal solutions for this problem with regard to possible variations of the processing time of certain tasks is investigated. Two heuristic procedures finding a compromise between the efficiency and the considered stability measure of studied solutions are suggested and evaluated on known benchmarks.

A goal programming mixed-model line balancing for processing time and physical workload