Assembly Line Design

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Format: Hardcover
Pub. Date: 2006-01-31
Publisher(s): Springer-Verlag New York Inc
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Summary

Efficient assembly line design is a problem of considerable industrial importance. Unfortunately, like many other design processes, it can be time-consuming and repetitive. In addition to this, assembly line design is often complex owing to the number of multiple components involved: line efficiency, cost, reliability and space for example. The main objective is to integrate the design with operations issues, thereby minimising its costs.Since it is impossible to replace a designer's intelligence, experience and creativity, it is important to provide him with a set of assistance tools in order to meet the conflicting objectives involved. Assembly Line Design presents three techniques based on the Grouping Genetic Algorithm (a powerful and broadly applicable optimisation and stochastic search technique) which can be used to aid efficient assembly line design:• 'equal piles for assembly lines', a new algorithm introduced to deal with assembly line balancing (balancing stations' loads);• a new method based on a multiple objective grouping genetic algorithm (MO-GGA) aiming to deal with resource planning (selection of equipment to carry out assembly tasks);'• balance for operation' (BFO), introduced to deal with the changes during the operation phase of assembly lines.Assembly Line Design will be of interest to technical personnel working in design, planning and production departments in industry as well as managers in industry who want to learn more about concurrent engineering. This book will also be of value to researchers and postgraduate students in mechanical, manufacturing or micro-engineering.

Author Biography

Rekiek Brahim received a license in Physics from the Univetsit+¬ Abdel Malek Essaadi, Tetouan and the D.E.S in production and robotics at the Universit+¬ Libre de Bruxelles (U.L.B.), Brussels in 1994 and 1996, respectively. He received his Ph.D. degree in Artificial Intelligence in 2000 from the Universit+¬ Libre de Bruxelles. Much of his work was carried out in collaboration with industrial companies. From 2001 to 2002, he worked as a member of the Sales Marketing Service at Fabricom Airports Systems, Brussels, Belgium. Since 2002, he has been working as a member of the Projects Management team. He has been an analyst and project manager responsible for the development of the baggage handling systems of many airports. His interests include software architecture, systems design, concurrent engineering, and artificial intelligence.Alain Delchambre obtained his Master and Phd degrees in Mechanical Engineering from the University of Brussels (ULB) in 1983 and 1990 respectively. After three years in industry, he joined a research centre for the Belgian Metalworking Industry (CRIF/WTCM). Since 1994, he has been a Professor at the Faculty of Applied Sciences in ULB and is head of the CADCAM department. He has published three books and more than 80 papers in the areas of concurrent engineering, computer aided design and genetic algorithms.

Table of Contents

Part I Assembly Line Design Problems
Designing Assembly Lines
3(4)
Introduction
3(1)
Assembly Line Design
3(2)
Designing or Optimising?
5(1)
Layout of the Book
6(1)
Design Approaches
7(6)
Introduction
7(1)
Why the Design is Difficult?
8(1)
Design and Search Approaches
8(1)
The Gap Between Theory and Practice
8(2)
Input Data
9(1)
Multiple Objective Problem
9(1)
Variability
9(1)
Scheduling
9(1)
Layout
10(1)
About the Quality of a Design
10(1)
Assembly Line Design Evolution
10(3)
Assembly Line: History and Formulation
13(18)
Introduction
13(1)
Evolution of Today's Manufacturing Issues
13(2)
First Metals
13(1)
Carpenters and Smiths
13(1)
Cottage Industries
14(1)
Factory System
14(1)
Mass Production
14(1)
Computers in Manufacturing
15(1)
Assembly Line Systems
15(1)
Notation and Definitions
16(3)
Assembly Line Balancing Problems
19(8)
Assembly Line Models
19(1)
Variability of Tasks Process Time
20(1)
Line Configuration
21(2)
Additional Constraints
23(2)
Assembly Line Design Problems
25(2)
Why is the Balancing Problem Hard to Solve?
27(4)
Part II Evolutionary Combinatorial Optimisation
Evolutionary Combinatorial Optimisation
31(8)
Introduction
31(1)
System Organisation
31(1)
How Do Genetic Algorithms Work?
32(6)
Representation
33(1)
Initialisation of the Population
34(1)
Sampling Mechanism
35(1)
Genetic Operators
36(2)
Landscapes and Fitness
38(1)
Population
38(1)
Simple... but it Works!
38(1)
Multiple Objective Grouping Genetic Algorithm
39(20)
Introduction
39(1)
Multiple Objective Optimisation
39(1)
The State of the Art
40(4)
The Use of Aggregating Functions
41(1)
Non-Pareto Approaches
41(1)
Pareto-based Approaches
42(1)
Preferences and Local Search Methods
42(1)
Constrained Problems
43(1)
Grouping Problems and the Grouping Genetic Algorithm
44(2)
Encoding Scheme
44(1)
Crossover Operator
45(1)
Mutation Operator
46(1)
Inversion Operator
46(1)
Multiple Objective Grouping Genetic Algorithm
46(5)
Control Strategy
47(1)
Individual Construction Algorithm
48(1)
Overall Architecture of the Evolutionary Method
48(1)
Branching on Populations
49(2)
The Detailed Example
51(8)
Part III Assembly Line Layout
Equal Piles for Assembly Line Balancing
59(18)
Introduction
59(1)
The State of the Art
59(3)
Exact Methods
59(2)
Approximated Methods
61(1)
Equal Piles for Assembly Line Balancing
62(9)
Motivation and Inspiration From Nature
63(1)
Input Data
64(1)
Customising the Grouping Genetic Algorithm to the Equal Piles Assembly Line Problem
64(5)
Experimental Results
69(2)
Extension to Multi-product Assembly Line
71(6)
Multiple Objective Problem
71(1)
Overall Architecture
72(5)
The Resource Planning for Assembly Line
77(16)
Introduction
77(1)
The State of the Art
78(1)
Dealing with Real-world Hybrid Assembly Line Design
79(5)
Cost
79(1)
Process Time
80(2)
Availability
82(1)
Station Space
83(1)
Incompatibilities Among Several Types of Equipment
84(1)
Input Data
84(1)
Overall Method
85(7)
Distributing Tasks Among Stations
85(1)
Selecting Equipment
86(3)
Heuristics
89(1)
Dealing with a Multi-product Assembly Line
90(1)
Complying with Hard Constraints
91(1)
Application of the Method
92(1)
Balance for Operation
93(12)
Introduction
93(1)
Multi-product Assembly Line
93(1)
The State of the Art
94(1)
Classical Methods
94(1)
Heuristics
95(1)
Ordering Genetic Algorithm
95(4)
Algorithm
95(2)
Heuristics
97(2)
Balance for Operation Concept
99(6)
Non-fixed Number of Stations
100(2)
Fixed Number of Stations
102(3)
Part IV The Integrated Method
Evolving to Integrate Logical and Physical Layout of Assembly Lines
105(16)
Introduction
105(1)
The State of the Art
105(1)
Assembly Line Design
106(1)
Integrated Approach
106(10)
Development of the Interactive Method
108(7)
Global Search Phase
115(1)
Application
116(5)
Concurrent Approach to Design Assembly Lines
121(16)
Introduction
121(1)
Concurrent Approach
121(1)
Assembly Line Design
122(2)
Data Preparation Phase
123(1)
Optimisation Phase
124(1)
Mapping Phase
124(1)
Case Studies
124(13)
Assembly Line Balancing Application: Outboard Motor
125(3)
Resource Planning Application: Car Alternator
128(9)
A Real-world Example Optimised by the OptiLine Software
137(8)
Conclusions and Future Work
145(4)
We Attained
145(1)
Tendencies and Orientations
145(1)
Data Collection
146(1)
Model Formulation
146(1)
Validation and Output Analysis
146(1)
The Proposed Approach
147(2)
References 149(10)
Index 159

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