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Transcript of Model of Spine Configuration Assembly Line Design for a Product Family By Dida D Damayanti...
![Page 1: Model of Spine Configuration Assembly Line Design for a Product Family By Dida D Damayanti (ITTelkom, Indonesia) Isa Setiasyah Toha (ITB, Indonesia)](https://reader035.fdocuments.us/reader035/viewer/2022081401/5a4d1b767f8b9ab0599b7552/html5/thumbnails/1.jpg)
Model of Spine Configuration Assembly Line Design for a
Product FamilyBy
Dida D Damayanti (ITTelkom, Indonesia)
Isa Setiasyah Toha (ITB, Indonesia)
![Page 2: Model of Spine Configuration Assembly Line Design for a Product Family By Dida D Damayanti (ITTelkom, Indonesia) Isa Setiasyah Toha (ITB, Indonesia)](https://reader035.fdocuments.us/reader035/viewer/2022081401/5a4d1b767f8b9ab0599b7552/html5/thumbnails/2.jpg)
OutlineIntroduction
Sub-lines Networking
Conclusion
Model of spine assembly line design
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INTRODUCTION
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MIXED-MODEL ASSEMBLY LINE
PLATFORM VARIANT PRODUCTS
Produk A Produk B Produk C
Product Family
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The Drawbacks of Mixed-model line
Increasing variation and assembly operations, caused:
Increasing in line management complexity
Decreasing in line efficiency
Decreasing in line flexibility
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Spine Assembly LineA layout consisting of a main aisle used as a
designed skeleton with some cells located in other sides [Langevin, et. al, 1994; Benjafar, et. al, 2006]
Designed to connect some sub-assembly lines as the modular structure of a product family
Variation and line length problem in mixed model assembly line, can be solved by taking the benefits
of assembly operation commonality in a product family [He and Kusiak, 1997].
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Objective
Develop a model of spine assembly line design based on the modular structure of a product family
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SUB LINES NETWORKING
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Family Product SubassembliesCommon subassemblies (CS): basic subassembly
Unique subassemblies (US): used in a certain variant products
Variant subassemblies (VS): have a similar function, but may be different in shape or quality to
differentiate each variant product
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Example of Product Family Architecture
CS VS
US-1 US-2
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Combined Precedence Diagram
6 8
7
4
2Start FinishCS
US-2
US-1
1
3
5
VS
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Connection Between Lines
St 1
St 2
US-1 Line
St 1
St 2
St 3US-2 Line
St 1 St 2 St 3 St 4
CS Line
12 3
4 5
6
7 8
St 1 St 2 St 3 St 4
VS Line
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MODEL OF SPINE ASSEMBLY LINE DESIGN
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Spine Assembly Line Modelling Process
QE MakespanC
bb
V
bb
EB
q
qCC 1
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Model of VS line design• It is a mixed model assembly line• The line is controlled as unpaced line• The MPS is sequenced by the STPT rule.• Decision variables of the model are assembly
operations allocation, number of workstations, and time between minimal part set (MPS).
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Model of VS line design• The objective function: to minimize the total operational
costs, consist of operation costs, idle time cost in each workstation, and waiting cost for each product.
• The model constraints: allocation constraint, precedence constraint, station time constraint, cycle time constraint, idle time and waiting time constraint, and workstation constraint.
PM M M P
11 1 2 1 2
. β D δ Dλdumk ik k k ik
k k i k i
Min TOE y f f f
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Model of VS line designObjective function:
PM M M P
11 1 2 1 2
. β D δ Dλdumk ik k k ik
k k i k i
Min TOE y f f f
(1) Constraints:
M
1
1jkk
x
, j=1,2,...N (2)
M M
1 1
. . ,hk jkk k
k x k x
j=1,2,...N and h Gj (3)
V N
1 1
w 0,bj jk ib ikb j
x a
i = 1,2,...,P and k=1,2,...M
(4)
1 ,dumk ka a k=1,2,...M (5)
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Model of VS line designP
1 11
( ) D Q Cdumk ik ik k k
i
f a f f f
,
k=1,2,...M (6)
1 0,if i = 1,2,...,P (7) 1
1 11
0,k
s ks
a f
k=2,...M (8)
1
( 1) ( 1)1 1
i i
r k r k rk rk ik ikr r
a f a f a
,
k=2,...M, r = 1,...,i and i = 2,...,P (9)
P P
( 1) ( 1) ( 1) ( 1)1 1
dum dum dumk k i k i k ik ik k
i i
a f a f a f f
k=2,...M and i = 2,...,P (10)
N
1
N 0,jk kj
x y
k=1,2,...M (11)
1 0,s sy y s=1,2,...(k-1) and k=2,...M (12)
, , 0,1jk k ibx y , j=1,2,...N and k=1,2,...M (13)
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Model of CS line design• CS line is a single assembly line and it is assumed that buffer is
always available in CS line.• The objective function of CS line design: to minimize the total
operational costs, consist of operation costs, idle time cost in each workstation, and waiting cost to VS line.
• The model constraints: allocation constraint, precedence constraint, idle time constraint, cycle time and waiting time constraint, and workstation constraint.
M M
1 1
. β Qδ Qλk kk k
Min TOS y f
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Model of US line design• US line is a single assembly line, its demand depends on the
variant using the US.• The objective function of US line design: to minimize the total
operational costs, consist of operation cost, idle time cost in each workstation, waiting cost in the first production and waiting cost to VS line.
• The model constraints: allocation constraint, precedence constraint, idle time constraint, cycle time and waiting time constraint, and workstation constraint.
M M M
1 1 2
. β Qδ ( 1) δ Qλk k kk k k
Min TOS y f k d y
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Numerical Example• Numerical example is provided to illustrate the
operational of the model. • Data Product Family A: demand, cost, and combined
precedence diagrami Variant Product Demand 1 V1 100 2 V2 50 3 V3 50
Total 200
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Numerical Example
1
2
12
11,11,11
10,10,12 18
7,6,9
15
6,10,0
11
11,8,13
14
0,4,6
10
18
15,15,0
20
10,10,0
21
7,7,0
19
5,5,0
17
12,12,0
16
9,9,0
8
11,11,11
7
6,6,66,4,7
3 4
8,8,8
6
4,4,4
5
3,3,39
10,10,10
5,5,5
7,7,7
Start
Finish
Assembly operation n, a,b,c: operation time V1, V2, dan V3
a,b,c
n :
CS
VS
US
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Numerical Example
Eff-1
St1 St213,12,12,10 12,10,10,10 St3 St419,11,11,12 9,13,13,16
12
8
1011
14
13
15
St1 St213 14 St3 14
52
3
67
4 9
1
St1 St217 17 St3 15
161819
21
2017
VS
US
CS
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Numerical Example
1 2 3 4
1 2
1 2 3
CS
US
VS
3
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Discussion• Spine assembly line:
– Shorten a mixed-model (VS) assembly line: lessen complexity
– More flexible to variation changes– Increase the operation efficiency: mass production (CS
Line), adjusted cycle time (US)– Support the issue of mass customization, postpone for
differentiation, and reconfigurable assembly line
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Conclussion• The spine assembly line for a product family consist of common
subassembly (CS) lines, unique subassembly (US) lines, and a variant subassembly (VS) line.
• The spine assembly line is designed in three sequential stages: design of VS line, design of CS and US lines, and connect CS and US to VS to make the spine assembly line configuration.
• By this line configuration, the complexity of the mixed model line is declined. The assembly operation similarities at the CS and US line could contribute to a more simple, flexible and efficient product family assembly line.
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References• J. Buchin, and M. Masin, “Multi-Objective Design of Team Oriented Assembly Systems”, European Journal of Operational Research, no. 132,
pp. 346-364, 2003.• A. Langevin, B. Montreuil, and D. Riopel, “Spine layout design”, International Journal of Production Research, vol. 32 no. 2, pp. 429-442, 1994.• S. Benjafaar, S. Heragu, and S. Irani, “Next Generation Factory Layouts: Research and Challenges and Recent Progress” , Interfaces, vol. 32 no.
6, pp. 58-76, 2002.• P. De Lit, A. Delchambre, and J. M. Henrioud, “An Integrated Approach for Product Family and Assembly System Design”, IEEE Transactions on
Robotics and Automation, vol. 19 no. 2, pp. 324-334, 2003.• D. W. He and A. Kusiak, “Design of Assembly Systems for Modular Products”, IEEE Transactions on Robotics and Automation, vol. 13 no.5, pp.
646-655, 1997.• D. D. Damayanti, A. Ma’ruf, B. P. Iskandar, and I. S. Toha, “Perancangan Lintasan Perakitan untuk Suatu Famili Produk”, Jurnal Teknik dan
Manajemen Industri, vol. 27 no. 1, pp. 1-12, 2007.• C. Becker and A. Scholl, “A Survey on Problems and Methods in Generalized Assembly Line Balancing”, European Journal of Operational
Research, no. 168, pp. 694–715, 2006.• C. Merengo, F. Nava, and A. Pozzetti, “Balancing and Sequencing Manual Mixed-Model Assembly Lines”, International Journal of Production
Research, vol. 37 no. 12, pp. 2835-2860, 1999.• A. Scholl and C. Becker, “State-of-the-Art Exact and Heuristic Solution Procedures for Simple Assembly Line Balancing”, European Journal of
Operational Research no. 168, pp. 666–693, 2006.• S. Gupta, and V. Krishnan, “Product Family-Based Assembly Sequence Design Methodology”, IIE Transactions in Design and Manufacturing, 30
(10), pp. 933-945, 1998.