In the automotive industry, assembly lines are used to produce vehicles. These assembly lines improve throughput, and need to be carefully planned. Planning, or balancing, an assembly line constitutes identifying precedence relationships between tasks in the assembly line, and assigning tasks to stations to fit some criteria. This procedure is costly to do by hand, and is well-suited for some level of automation. The problem of balancing assembly lines has been researched since the 1950’s, but modern assembly lines largely rely on engineers to balance the line by hand. This thesis proposes that the work flow of engineers planning the assembly line would be improved by a group decision support system. This group decision support system could supply engineers with proposals for assembly lines, which the engineers can choose to modify further, either by hand or with the decision support system. The group decision support system is realized with a distributed system, consisting of a front-end, a back-end, an application programming interface to balance assembly lines, and two databases. The front-end is a website, where the users can create problems with a precedence graph. The back-end allows data to be permanently stored in the two databases, and allows communication with the application programming interface. The contribution of this thesis is a proof of concept of a group decision support system that can solve two basic types of assembly line balancing problems, SALBP-1 and SALBP-2. During development it was found that the developed system was generic enough to support different types of tasks, such as planning cooking. Further development is needed to use the system in an industrial setting, as real assembly lines need more complex models than the current version support.

Les travaux de cette thèse concernent la conception et l’optimisation de lignes de transfert reconfigurables. L’objectif principal est de concevoir une ligne d’usinage à moindre coût tout en respectant les contraintes techniques, technologiques et économiques du problème. Le problème d’optimisation correspondant est un problème d’équilibrage de lignes d’usinage sujet à des contraintes spécifiques. Il consiste à affecter les opérations aux stations de travail en minimisant les coûts d’installation. En plus des contraintes habituelles de ce type de problème, à savoir, les contraintes de précédence, d’inclusion et d’exclusion, nous avons dû considérer des contraintes d’accessibilité. De plus, la spécificité principale des lignes reconfigurables par rapport aux lignes de transfert dédiées, vient de la réalisation en série des opérations. Celle-ci rend souvent nécessaire la mise en place de stations équipées de plusieurs centres d’usinage travaillant en parallèle pour obtenir les volumes de production souhaités. Enfin, l’utilisation d’une tête d’usinage mono-broche induit la prise en compte de temps inter-opératoire de déplacements et de changement d’outils qui dépendent de la séquence d’opérations. Dans un premier temps, nous avons proposé une modélisation mathématique du problème à l’aide d’un programme linéaire en nombres mixtes. Nous avons aussi développé des méthodes de calcul de bornes inférieures ainsi qu’une procédure de prétraitement. Cependant, les contraintes additionnelles rendent la résolution du problème d’équilibrage plus difficile que dans le cas des lignes dédiées, et l’approche proposée ne permet généralement pas de résoudre des instances de taille industrielle. Pour répondre à ce besoin, nous avons donc développé plusieurs méthodes de résolution approchées du problème en nous inspirant de métaheuristiques efficaces sur des problèmes d’optimisation combinatoire. / This work concerns the design and the optimization of reconfigurable transfer lines. The principle objective is to design a machining line with less cost while respecting the technological and economic constraints of the problem. The corresponding optimization problem is a transfer lines balancing problem subject to specific constraints. It consists to affect operations to workstations minimizing the installations cost. In addition to the habitual constraints of the transfer balancing problem, i.e. precedence, inclusion and exclusion constraints, we consider accessibility constraints. In addition, the principal specificity of reconfigurable lines compared to the dedicated transfer lines, comes from the sequential execution of operations. This often makes it necessary to set up stations with several machining centers working in parallel to achieve desired production volumes. Finally, the utilization of mono-spindle head machining center induces the inclusion of setup times between operations. This setup time is due to the time of displacement and change of tools which it depends of the operational sequence. We proposed firstly a mathematical formalization of the problem using a mixed integer program. We developed also several methods to calculate lower bounds and a pretreatment procedure. However, the additional constraints make the resolution of the considered balancing problem very difficult and the proposed approach generally does not solve instances of industrial size. To meet this need, we have developed several approximate resolution methods of the problem taking inspiration from effective Metaheuristics on combinatorial optimization problems.

The global competitive environment and the growing demand for personalised products have increased the interest of companies in producing similar product models on the same assembly line. Companies are forced to make significant structural changes to rapidly respond to diversified demands and convert their existing single-model lines into mixed-model lines in order to avoid unnecessary new line construction cost for each new product model. Mixed-model assembly lines play a key role in increasing productivity without compromising quality for manufacturing enterprises. The literature is extensive on assembling small-sized products in an intermixed sequence and assembling large-sized products in large volumes on single-model lines. However, a mixed-model parallel two-sided line system, where two or more similar products or similar models of a large-sized product are assembled on each of the parallel two-sided lines in an intermixed sequence, has not been of interest to academia so far. Moreover, taking model sequencing problem into consideration on a mixed-model parallel two-sided line system is a novel research topic in this domain. Within this context, the problem of simultaneous balancing and sequencing of mixed-model parallel two-sided lines is defined and described using illustrative examples for the first time in the literature. The mathematical model of the problem is also developed to exhibit the main characteristics of the problem and to explore the logic underlying the algorithms developed. The benefits of utilising multi-line stations between two adjacent lines are discussed and numerical examples are provided. An agent-based ant colony optimisation algorithm (called ABACO) is developed to obtain a generic solution that conforms to any model sequence and it is enhanced step-by-step to increase the quality of the solutions obtained. Then, the algorithm is modified with the integration of a model sequencing procedure (where the modified version is called ABACO/S) to balance lines by tracking the product model changes on each workstation in a complex production environment where each of the parallel lines may a have different cycle time. Finally, a genetic algorithm based model sequencing mechanism is integrated to the algorithm to increase the robustness of the obtained solutions. Computational tests are performed using test cases to observe the performances of the developed algorithms. Statistical tests are conducted through obtained results and test results establish that balancing mixed-model parallel two-sided lines together has a significant effect on the sought performance measures (a weighted summation of line length and the number of workstations) in comparison with balancing those lines separately. Another important finding of the research is that considering model sequencing problem along with the line balancing problem helps algorithm find better line balances with better performance measures. The results also indicate that the developed ABACO and ABACO/S algorithms outperform other test heuristics commonly used in the literature in solving various line balancing problems; and integrating a genetic algorithm based model sequencing mechanism into ABACO/S helps the algorithm find better solutions with less amount of computational effort.

Submitted by Luciana Ferreira (lucgeral@gmail.com) on 2017-08-03T11:05:17Z No. of bitstreams: 2 Dissertação - Carlos Alexandre Xavier da Silva - 2017.pdf: 2190162 bytes, checksum: 7c5e13d2301a93a75a0e2d68e1b9a893 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) / Approved for entry into archive by Luciana Ferreira (lucgeral@gmail.com) on 2017-08-03T11:06:02Z (GMT) No. of bitstreams: 2 Dissertação - Carlos Alexandre Xavier da Silva - 2017.pdf: 2190162 bytes, checksum: 7c5e13d2301a93a75a0e2d68e1b9a893 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) / Made available in DSpace on 2017-08-03T11:06:02Z (GMT). No. of bitstreams: 2 Dissertação - Carlos Alexandre Xavier da Silva - 2017.pdf: 2190162 bytes, checksum: 7c5e13d2301a93a75a0e2d68e1b9a893 (MD5) license_rdf: 0 bytes, checksum: d41d8cd98f00b204e9800998ecf8427e (MD5) Previous issue date: 2017-06-26 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior - CAPES / In one version of the Simple Assembly Line Balancing Problem (SALBP) tasks are assigned to stations along an assembly line with a fixed cycle time in order to minimise the required number of stations. It is assumed that the total work needed for each product unit has been partitioned into economically indivisible tasks. In practice, it may be that the minimal number of stations can be reduced when it is possible to further divide particular tasks in limited ways even with additional time penalty costs. Allowing task division leads to a new assembly line balancing problem, TDALBP (Task Division Assembly Line Balancing Problem) and a solution procedure for it. This work introduces a mathematical model for the TDALBP and presents promising computational results for the adaptation of some classical SALBP instances from the research literature. The results demonstrate that the TDALBP has the potential to significantly improve assembly line performance. / O balanceamento eficaz de uma linha de produção é importante para aprimorar a produtividade e reduzir custos de uma industria. O problema do balanceamento de linhas de produção (Assembly Line Balancing Problem - ALBP) envolve atribuir as tarefas necessárias para produzir cada unidade de um produto entre estações de trabalho ao longo de uma linha de produção, a fim de otimizar alguma medida de desempenho do sistema. Tradicionalmente, supõe-se que o trabalho total necessário para cada unidade de produto foi particionado em tarefas economicamente indivisíveis, de modo que uma maior divisão gera custos desnecessários. Assim, cada tarefa requerida não pode ser dividida e deve ser realizada em uma única estação. Na prática, no entanto, isso pode não ser sempre verdadeiro quando existe um objetivo orientado ao tempo, tal como a minimização do número de estações para um determinado tempo de ciclo. Neste caso, pode ser que o número mínimo das estações possa ser reduzido quando for possível continuar a dividir tarefas particulares de formas limitadas, mesmo se a divisão induzir custos adicionais de tempo. A permissão de tal divisão de tarefas nos leva a um novo problema de balanceamento de linhas de produção, o qual denotamos por TDALBP (Task Division Assembly Line Balancing Problem). Nós propomos um modelo de programação linear inteira binária para o TDALBP e procedimentos efetivos para solucioná-lo. Os procedimentos foram avaliados sobre adaptações de várias instâncias SALBP clássicas da literatura. Os resultados computacionais são promissores e mostram o potencial do TDALBP para a melhora significativa do desempenho de linhas de produção.

This thesis deals with the analysis of data obtained by observing and measuring workplaces of assembly lines with a focus on the efficiency of their utilization, through selected elements of industrial engineering, which the reader can get acquainted with in the theoretical part of the thesis. In this thesis the line productivity during the shifts is analyzed, an ideal line balancing condition is defined and suggestion for changing the time of line consumption norm according to the measured line cycle time is made. According to the complex analyzes of the workplaces, suggestions are concluded and an economic appreciation of these proposals is also elaborated. The author of this thesis finds the main benefit of this work in increasing of the productivity of the analyzed line in the case of implementation of solution designs.

Due to the changes and improvements that have occurred over the years, the manufacturing sector has evolved. Companies in the 21st-century face changes in the marketplace that are difficult to predict due to international competition and the rapid emergence of new products. To cope, companies must reinvent themselves and design manufacturing systems that seek to produce quality and low-cost products, and respond to the changes that must be faced. These capabilities are encompassed in reconfigurable manufacturing systems (RMS), capable of dealing with uncertainties quickly and economically. On the other hand, production planning with this type of system presents a significant challenge. Although simulation-based optimization techniques have been applied to address certain RMS challenges, only a few studies have applied simulation-based multi-objective optimization to simultaneously address several conflicting design objectives, as is the case in this project. This project aims to investigate some aspects using SBMO that directly affect the performance of a plant and demonstrate the usefulness of the method. / <p>Det finns övrigt digitalt material (t.ex. film-, bild- eller ljudfiler) eller modeller/artefakter tillhörande examensarbetet som ska skickas till arkivet.</p>

Volvo CE at Hallsberg, Sweden is specialized in the production of cabs for construction equipment. The organization employs the one-line (mixed-model assembly) method, where cabs for different products are all assembled on the same main line. Operations on the main line are not standardized for all products. The future vision of the company is to establish the fishbone factory concept, where the diversity is introduced in sub-flows and variation is reduced on the main line.This is primarily to reduce balancing losses and eventually reduce the total throughput time of the plant. The thesis work focuses on a new product known as the Next Gen Cab. These cabs are designed to support the fishbone factory concept. Next Gen cabs comprise of physical modules that provide different customer features, but are designed with standard interference and toolpoints. They follow the common architecture approach. The aim of this thesis work is to develop an assembly setup for the production of the front module within the next gen cabs, and investigate a suitable material feeding technique. The work also focuses on the transition phase, which comprise of the production of both existing and Next Gen cabs. The methodology used for the work includes the understanding of the current state to determine possibilities of utilizing the existing setup. The report explains part and process similarities between the existing cabs and Next Gen cabs which aids in the development of an assembly setup through line balancing. Two material feeding concepts have been developed and a framework has been established for part presentation at Point-of-Use. It is followed by a comparison of the concepts based on factors such as kitting time, headcount cost, stock value and required investment. The concepts are evaluated and finally, a conclusion is made along with a recommendation on how the company can proceed when the new products are introduced. / Volvo CE i Hallsberg, Sverige är specialiserat på produktion av hytter för entreprenadmaskiner. Organisationen använder en enkellinje metod (blandad-modellmontering), där alla hytter för olika produkter monteras på samma huvudlinje. Operationerna på huvudlinjen är inte standardiserad för alla produkter. Framtidsvisionen för företaget är att etablera fiskbensfabrikskonceptet, där mångfalden införs i delflöden och variationen minskas påhuvudlinjen. Detta är främst för att minska balanseringsförlusterna och så småningom minska anläggningens totala genomströmningstid. Examensarbetet fokuserar på en ny produkt som kallas Next Gen Cab. Dessa hytter är utformade för att stödja fiskbensfabrikskonceptet. NextGen-hytterna består av fysiska moduler som ger olika kundfunktioner, men är utformade med standardkopplingar och verktygspunkter. De följer den gemensamma arkitekturstrategin. Syftet med detta examensarbete är att utveckla ett monteringsupplägg för framställning av frontmodulen inom next gen hytter, och undersöka lämplig materialmatningsteknik. Arbetet fokuserar också på övergångsfasen, som består av produktion av både befintliga och NextGen-hytter. Metoden som används för arbetet inkluderar förståelse för det aktuella tillståndet för att bestämma möjligheterna att använda den befintliga uppställningen. Rapporten förklarar likheter mellan delar och processer för de befintliga hytterna och Next Gen-hytterna vilket hjälper till att utveckla en monteringsuppställning genom linjebalansering. Två materialförsörjningskoncept har utvecklats och ett ramverk har skapats för delpresentation vid Point of-Use. Detta följs av en jämförelse av koncepten baserat på faktorer som ”kittnings”-tid, antal anställda, aktievärde och nödvändiga investeringar. Koncepten utvärderas och utmynnar i en slutsats tillsammans med en rekommendation om hur företaget kan gå vidare när de nya produkterna introduceras.

Future manufacturing will be characterized by the complementarity between humans and automation (human-robot collaboration). This requires new methods and tools for the design and operation of optimized manufacturing workplaces in terms of ergonomics, safety, efficiency, complexity management and work satisfaction. There have been some efforts in the recent years to propose a tool for determining optimal human-automation levels for load balancing. Although the topic is quite new, it shares some similarities with some of the existing research in the area of robotic assembly line balancing. Therefore, it is crucial to review the existing literature and find the most similar models and methods to facilitate the development of new optimization models and algorithms. One of the two contributions that this thesis gives to the research world in the RALBP context is a literature review that involves high quality articles from 1993 to beginning 2018. This literature review includes visual and comprehensive tables—and a label system— where previous research patterns and trends are highlighted. Visualization of data and results obtained by assembly line optimization tools is a very important topic that has rarely been studied. Data visualization would provide a: 1. better comprehension of patterns, trends and qualitative data 2. more constructive information absorption 3. better visualization of relationships and patterns between operations, and 4. better contribution to data manipulation and interaction. The second contribution to research found in this thesis is the use of a human modelling (DHM) tool (called IPS), which is proposed as an assessment to the ergonomic risk that a robotic assembly line may involve. This kind of studies are necessary in order to reduce one of the most frequent reasons of work absence in our today society i.e. musculoskeletal disorders (MSDs). MSDs are often the result of poor work environments and they lead to reduced productivity and quality losses at companies. In view of the above, IPS was used in order to resolve the load handling problem between human and robot, depending on their skills and availability, while fulfilling essential ISO standards i.e. 15066 and 10218:1 and :2. The literature review made it possible to select highly useful documents in developing assumptions for the experiment and contributed to consider real features detected in the industry. Results show that even though IPS is not capable of calculating an entire robotic assembly with human-robot collaboration, it is able to simulate a workstation constituted of one robot and one human. Finite and assembly motions for both human and robot are expected to be implemented in future versions of the software. Finally, the main advantages of using DHM tools in assessing ergonomic risks in RALB can be extracted from the results of this thesis. This advantages include 1. ergonomic evaluation for assembly motions 2. ergonomic evaluation for a full working day (available in future version) and 3. essential ISO standard testing (available in future version).

Une vue d'ensemble des problèmes et des méthodes pour la conception des lignesd'assemblage et d'usinage est donnée. Un nouveau problème d'affectation de la main-d’œuvrepour une ligne d'assemblage multi-produit cadencée avec un objectif de minimiser lenombre d'opérateurs est étudié. Diverses relations de priorité entre les opérations et lesdifférentes fonctions définissant les temps d'opérations, en fonction du nombre d'opérateurssont considérés. Un nouveau problème d'optimisation multiobjectif pour une ligne d'usinagemono-produit est formulé. Plusieurs méthodes exactes et heuristiques et leursimplémentations informatiques pour les deux problèmes sont développées par l'auteur. Unmodule logiciel d'aide à la décision pour résoudre ces problèmes est développé et implémentédans un environnement d'un nouveau PLM d'IBM dans le cadre du projet européen amePLM.Ce module est testé sur un exemple réel de conception d'une ligne de montage des moteurschez Mercedes Benz en Allemagne. / An overview of existing problems and methods for the design of assembly and transfer lines is given. A new workforce assignment problem for a paced multi-product assembly line with a goal of minimizing the number of workers is studied. Various precedence relations between operations and functions of operation processing times dependent on the number of workers areconsidered. A new problem of multi-objective optimization for a single product transfer line is solved. Several exact and heuristic methods and their computer implementations for both problems are developed by the author. An application of developed approaches to solving a real production problem relevant to the European project amePLM is demonstrated.

Submitted by YURI PRADO DE SOUZA (yuriprado.uff@gmail.com) on 2018-10-17T22:40:46Z No. of bitstreams: 1 Dissertação v60 - final.pdf: 1880394 bytes, checksum: 1c4ca28a4089a492a49b54e291c33dea (MD5) / Rejected by Pamella Benevides Gonçalves null (pamella@feg.unesp.br), reason: Solicitamos que realize correções na submissão seguindo as orientações abaixo: Rever a ordenação dos elementos pré-textuais ... capa, folha de rosto ... ficha catalográfica ... • A capa e ficha catalográfica não são consideradas para contagem de páginas. a paginação deve aparecer no canto superior direito a partir da introdução, realizei a contagem das páginas e seu trabalho deve com o número (14)*, após você precisa atualizar a numeração na ficha catalográfica, nas listas e no sumário. • Resumo: Apenas palavra Resumo e Abstract devem ser centralizada; o resumo deve ser em parágrafo único. 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No. of bitstreams: 1 souza_yp_me_guara.pdf: 1810118 bytes, checksum: 4638b9426aac62a064b565b38ffda481 (MD5) Previous issue date: 2018-08-27 / Neste trabalho propõe-se uma abordagem para o Problema de Balanceamento de Linhas de Montagem (do inglês, Assembly Line Balancing Problem - ALBP) para aumentar a eficiência de uma indústria montadora de veículos. O ALBP caracteriza-se como um problema de sequenciamento de tarefas em estações de trabalho classificado como um problema de Otimização Combinatória NP-difícil e, portanto, a solução exata do problema em ambientes reais geralmente implica em elevado custo computacional. Para resolver o ALBP, foram formulados um modelo matemático de otimização inteira mista para obtenção de soluções determinísticas e um modelo estocástico com recurso que considera a incerteza dos tempos de execução das tarefas pelos operadores. A motivação para o desenvolvimento do presente trabalho decorre da observação de interrupções constantes do fluxo de produção nesta indústria, atribuídas às mais diversas naturezas, e que causavam transtornos e elevados níveis de estresse aos trabalhadores. Ambos os modelos, determinístico e estocástico, aumentaram a capacidade de produção de 196 unidades/dia para 245 e 233 unidades/dia, respectivamente. O modelo estocástico aumentou o tempo de ciclo CT em 5,6% quando comparado ao modelo determinístico, embora diminua a capacidade efetiva em 4,8% Porém, não considerar a incerteza no tempo de execução das tarefas pode diminuir a quantidade produzida em até 10,6%. Contrariamente ao entendimento comum em linhas de montagem, este trabalho conclui que reduzir os tempos de ociosidade aos níveis mínimos é prejudicial à produtividade de linhas de montagem. Isto se deve ao fato de que uma parcela do tempo atribuído à ociosidade dos operadores, na verdade contêm um tempo adicional gerado pela incerteza do tempo de execução das tarefas. Os resultados sugerem que a abordagem do ALBP sob incerteza contribui para o aumento dos índices de capacidade operacional da empresa. Devido ao grande esforço computacional necessário para a solução dos modelos de otimização propostos (determinístico e estocástico), não se consegue resolver, em um tempo computacional razoável, exemplares de dimensões reais do problema. Em vista disto, o trabalho propõe também uma heurística para a solução do ALBP visando minimizar o tempo de ciclo. Experimentos computacionais sugerem que a heurística proposta obtém resultados razoáveis para grandes exemplares do problema em um tempo computacional pequeno / This work proposes solution approaches to the Assembly Line Balancing Problem (ALBP) to increase the efficiency of a vehicle assembler industry. The ALBP is characterized as a task sequencing in workstations which is classified as a NP-hard Combinatorial Optimization problem and, therefore, the exact solution of the problem in real environments usually implies a high computational cost. In order to solve the ALBP, a mathematical model of mixed integer optimization to obtain deterministic solutions and a stochastic model with resource that considers the uncertainty of the execution times of the tasks by the operators were formulated. The motivation for the development of this work stems from the constant interruptions of the production flow in this industry, attributed to the most diverse natures, which cause disorders and high levels of stress to the workers. The deterministic and stochastic models increased the production capacity from 196 units / day to 245 and 233 units / day, respectively. The stochastic model increased the cycle time by 5.6% when compared to the deterministic model, although it reduced the effective capacity by 4.8%, which is equivalent to 12 vehicles / day. However, not considering the uncertainty in task execution times can decrease the amount produced by up to 10.6% or 26 vehicles / day. Contrary to the most acceptable idea, this work concludes that reducing idle times to minimum levels is detrimental to assembly line productivity. This is due to the fact that a portion of the time attributed to the idleness of the operators actually contains an additional time generated by the uncertainty of the execution time of the tasks. The results suggest that the approach of the ALBP under uncertainty contributes to the increase of the indices of operational capacity of the company. Due to the great computational effort required to solve the proposed optimization models (deterministic and stochastic), it is not possible to solve real instances of the problem in a reasonable computational time. In view of this, this work also proposes a heuristic for the ALBP solution in order to minimize the cycle time. Computational experiments suggest that the proposed heuristic obtains reasonable results for large instances of the problem in a small computational time