2-Stage Design Method for Assembly Line Systems : A Unified Approach

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  • 組立ラインシステム(ALS)の2段階設計法 : 統一アプローチ
  • クミタテ ライン システム ALS ノ 2 ダンカイ セッケイホウ トウイツ アプローチ

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Abstract

Assembly factories often consist of multiple production stations connected by conveyors to transport and store materials. In assembly manufacturing, among systems using conveyors, there are two major types of array for unit stations : the line type and the flexible type, and they differ in material flows of processed and overflowed items. The former system is known as Assembly Line Systems (ALS), in which each station has the two cases with and without stoppers. This paper focuses on the case without stoppers, considers the design problem as a coordination problem between unit stations (Generalized CSPSs) by using the station-centered approach, and proposes a 2-Stage Design Method for integrating the line balancing and stochastic buffer design problems. In this method, the preliminary stage is to set an initial value for the cycle time given the number of stations, production planning quantity and production planning period. The first stage is to decide the economic cycle time for minimizing the total expected operating cost. The second stage is to decide the economic buffers for minimizing the total expected operating cost under the economic cycle time, and the first and second stages are repeated till the minimal cost is attained. First, we consider the station-centered vs. system-centered approach to the ALS without stoppers, and show the effectiveness of the former. Next, the 2-Stage Design Method by that approach is proposed, and the merits are shown by an optimal design example. In addition, generalizations about the given cycle time and finite working zone are numerically discussed.

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