Optimization Model for Identification of Assembly Alternatives of Large-Scale, Make-to-Order Products

Authors: Henrik Prinzhorn, Peter Nyhuis, Johannes Wagner, Peter Burggräf, Torben Schmitz, Christina Reuter

Abstract:

Assembling large-scale products, such as airplanes, locomotives, or wind turbines, involves frequent process interruptions induced by e.g. delayed material deliveries or missing availability of resources. This leads to a negative impact on the logistical performance of a producer of xxl-products. In industrial practice, in case of interruptions, the identification, evaluation and eventually the selection of an alternative order of assembly activities (‘assembly alternative’) leads to an enormous challenge, especially if an optimized logistical decision should be reached. Therefore, in this paper, an innovative, optimization model for the identification of assembly alternatives that addresses the given problem is presented. It describes make-to-order, large-scale product assembly processes as a resource constrained project scheduling (RCPS) problem which follows given restrictions in practice. For the evaluation of the assembly alternative, a cost-based definition of the logistical objectives (delivery reliability, inventory, make-span and workload) is presented.

Keywords: Assembly scheduling, large-scale products, make-to-order, rescheduling, optimization.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1125967

References:

[1] J. Potthast and S. Baumgarten, "Lean-Production-Methods for XXL-Products," Logistics Journal, vol. 10, no. 1, pp. 1-4, 2011.
[2] Y. Lang, Y. Yao, P. Xia and J. Li, "Virtual Assembly System for Large-Scale Complex Products," Applied Mechanics and Materials Vols. 10-12, pp. 444-450, 06 December 2008.
[3] B.-A. Behrens, L. Overmeyer, P. Nyhuis und R. Nickel, „XXL-Produkte - ein Trend in der Produktionstechnik,“ VDI-Z Integrierte Produktion, Bd. 35, Nr. 7, pp. 56-58, 2009.
[4] B. Lotter und H.-P. Wiendahl, Montage in der industriellen Produktion. Ein Handbuch für die Praxis., Berlin: Springer, 2012.
[5] B.-A. Behrens, P. Nyhuis, L. Overmeyer, A. Bentlage, T. Rüther und G. Ullmann, „Towards a definition of large scale products,“ Production Engineering , Bd. 8, Nr. 1-2, pp. 153-164, 2013.
[6] D. Swyt, „New concepts of precision dimensional measurement for modern manufacturing,“ in Manufacturing and Automation Systems, Waltham, Academic Press, 1992, pp. 111-162.
[7] M. Goudarzi und B.-A. Behrens, „Im Prinzip leicht,“ Sonne, Wind & Wärme, Bd. 13, Nr. 52, 2010.
[8] P. Rochow, P. Burggraef, C. Reuter, H. Prinzhorn, J. Wagner and T. Schmitz, "Identification of alternative assembly sequences for large-scale products," in Production and Operations Management Society - POMS 26th Annual Conference, May 8-11, 2015, Washington D.C., USA, 2015.
[9] A. Kampker, J. Wagner, P. Burggraef and Y. Baeumers, "Criticality-focused, pre-emptive disruption management in low-volume assembly," in Proceedings of the 23rd International Conference on Production Research (ICPR), Manila, Philippines, 2015.
[10] T. Petersen, Organisationsformen der Montage. Theoretische Grundlagen, Organisationsprinzipien und Gestaltungsansatz, Aachen: Shaker, 2005.
[11] A. Kampker, P. Burggraef and Y. Baeumers, "Economic level of detail for assembly planning," in 2014 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM 2014), December 9-12, 2014, Selangor Darul Ehsan, Malaysia, 2014.
[12] C. Reuter, P. Burggraef, C. Boening, T. Schmitz, J. Wagner und H. Prinzhorn, „Adaptive Montage für XXL-Produkte,“ ZWF - Zeitschrift für wirtschaftlichen Fabrikbetrieb, Bd. 109, Nr. 19, pp. 718-721, 2014.
[13] S. Meers, H. Gärtner und P. Nyhuis, „Logistische Herausforderungen in Produktionsnetzen,“ ZWF - Zeitschrift für wirtschaftlichen Fabrikbetrieb, Bd. 105, Nr. 11, pp. 949-952, 2010.
[14] Y. Lang, Y. Yao, P. Xia and G. Liu, "Research on Exact Placement Technology of Virtual Assembly for Large-Scale Products," Applied Mechanics and Materials, Vols. 10-12, pp. 460-465, 2008.
[15] X. Qia, J. Bard and G. Yu, "Disruption management for machine scheduling: The case of SPT schedules," International Journal of Production Economics, vol. 103, no. 1, pp. 166-184, 2006.
[16] A. Cauvin, A. Ferrarini and E. Tranvouez, "Disruption management in distributed enterprises: A multi-agent modelling and simulation of cooperative recovery behaviours," International Journal of Production Economics, vol. 122, no. 1, pp. 429-439, 2009.
[17] H.-P. Wiendahl, Fertigungsregelung - Logistische Beherrschung von Fertigungsabläufen auf Basis des Trichtermodells, München: Hanser, 1997.
[18] H. Lödding, Handbook of Manufacturing Control, Springer, 2013.
[19] F. Straube und H.-C. Pfohl, Trends und Strategien in der Logistik - Globale Netzwerke im Wandel, Bremen: DVV Media Group, 2008.
[20] J. Herrmann, Handbook of Production Scheduling, Springer US, 2006.
[21] E. Gutenberg, Grundlagen der Betriebswirtschaftslehre, Band 1: Die Produktion., Berlin: Springer, 1951.
[22] G. Vieira, "Rescheduling Manufacturing Systems: A Framework of Strategies, Policies And Methods," Journal of Schedule, pp. 39-62, 2003.
[23] W. Herroelen and R. Leus, "Project scheduling under uncertainty: Survey and research potentials," European Journual of Operational Research, no. 165, pp. 289-306, 2005.
[24] W. Herroelen and R. Leus, "Robust and reactive project schedling: a review and classification of procedures," International Journal of Production Research, vol. 42, no. 8, pp. 1599-1620, 2004.
[25] M. Pinedo, "Scheduling - Theory, Algorithms and Systems," Inst Management Sci, vol. 25, no. 4, pp. 130-132, 1995.
[26] L. Church and R. Uzsoy, "Analysis of periodic and event-driven rescheduling policies in dynamic shops," International Journal of Computer Integrated Manufacturing, vol. 5, no. 3, pp. 153-163, 2007.
[27] K. Baker and D. Peterson, "An analytical framework for evaluatiing rolling schedules," Management Science, vol. 25, no. 4, pp. 342-351, 1979.
[28] A. Muhlemann, A. Lockett and C.-K. Farn, "Job shop scheduling heuristics and frequency of scheduling," International Journal of Production Research, vol. 20, no. 2, pp. 227-241, 1982.
[29] M. Yamamoto and S. Nof, "Scheduling/rescheduling in the manufacturing operating system environment," International Journal of Production Research, vol. 23, no. 4, pp. 705-722, 1985.
[30] R.-K. Li, Y. Shyu and S. Adiga, "A heuristic rescheduling algorithm for computer-based production scheduling systems," International Journal of Production Research, vol. 31, pp. 1815-1826, 1993.
[31] J. Fang and Y. Xi, "A rolling horizon job shop rescheduling strategy in the dynamic environment," International Journal of Advanced Manufacturing Technology, vol. 13, pp. 227-232, 1997.
[32] H. Wu and R. Li, "A new rescheduling method for computer based scheduling systems," International Journal of Production Research, vol. 33, no. 8, pp. 2097-2110, 1995.
[33] R. Abumaizar and J. Svestka, "Rescheduling job shops under disruptions," International Journal of Production Research, vol. 35, pp. 2065-2082, 1997.
[34] M. Olumolade and D. Norrie, "Reactive scheduling system for cellular manufacturing with failure-prone machines," International Journal of Computer Integrated Manufacturing, vol. 9, no. 2, pp. 131-144, 1996.
[35] S. Wu, R. Storer and P.-C. Chang, "One-machine rescheduling heuristic with efficiency and stability as criteria," Computers & Operations Research, vol. 20, pp. 1-14, 1993.
[36] I. Sabuncuoglu and S. Karabuk, "Rescheduling frequency in an FMS with uncertain processing times and unreliable machines," Journal of Manufacturing Systems, vol. 18, no. 4, pp. 268-283, 1999.
[37] R. Kolisch and K. Hess, "Efficient methods for scheduling make-to-order assemblies under resource assembly area and part availability constraints," International Journal of Production Research, vol. 38, no. 1, pp. 207-228, 2000.
[38] O. Icmeli, S. Seluc Erenguc and C. Zappe, "Project Scheduling Problems: A Survey," International Journal of Operations & Production Management, vol. 13, no. 11, pp. 80-91, 1993.
[39] S. Ghosh and R. Gagnon, "A comprehensive literature review and analysis of the design, balancing and scheduling of assembly systems," International Journal of Production Research, vol. 27, no. 4, pp. 637-670, 2007.
[40] N. Boysen, M. Fliedner and A. Scholl, "A classification of assembly line balancing problems," European Journal of Operational Research, vol. 2, no. 183, pp. 674-693, 2007.
[41] M. Salveson, "The assembly line balancing problem," The Journal of Industrial Engineering, vol. 6, no. 3, pp. 18-25, 19955.
[42] C. Becker and A. Scholl, "A survey on problems and methods in generalized assembly line balancing," European Journal of Operational Research, vol. 168, pp. 694-715, 2006.
[43] F. Chan, T. Wong and L. Chan, "An evolutionary algorithm for assembly job shop with part sharing," Computers & Industrial Engineering, pp. 641-651, 3 Dezember 2008.
[44] O. Kheirandish, R. Tavakkoli-Moghaddam and M. Karimi-Nasab, "An artificial bee colony algorithm for a two-stage hybrid flow shop scheduling problem with multilevel product structures and requirements," International Journal of Computer Integrated Manufacturing, vol. 28, no. 5, pp. 437-450, 5 February 2014.
[45] V. Dalfard, A. Ardakani and T. Banihashemi, "Hybrid Genetic Algorithm for Assembly Flow-Shop Scheduling Problem with sequence-dependent setup and transportation times," 2011.
[46] M. Gomes, A. Barbosa-Póvoa and A. Novais, "Reactive schedling in make-to-order flexible job shop with re-entrant process and assembly: a mathematical programming approach," International Journal of Production Research, vol. 51, no. 17, pp. 5120-5141, 2013.
[47] M. Mastrolilli and L. Gambardella, "Effective Neighborhood Functions for the Flexible Job Shop Problem," Technical Report n. IDSIA-45-98, Lugano, Switzerland, 1998.
[48] D. Eyres, Ship Construction, Oxford: Butterworth-Heinemann, 2007.
[49] J. Liker and L. Thomas, "What is Lean Ship Construction and Repair?," Journal of Ship PRoduction, vol. 18, no. 3, pp. 121-142, 2022.
[50] L. Zhuo, D.-C. Kim Huat and K. Wee, "Scheduling dynamic block assembly in shipbuilding through hybrid simulation and spatial optimization," International Journal of Production Research, vol. 50, no. 20, pp. 5986-6004, 2012.
[51] J.-D. Caprace, C. Petcu, M.-G. Velarde and P. Rigo, "Optimization of shipyard space allocation and scheduling using a heuristic algorithm," Journal of Marine Science and Technology, 2013.
[52] R. Kolisch, "Serial and parallel resource-constrained project scheduling methods revisited: Theory and computation," European Journal of Operational Research, no. 90, p. 320, 1996.
[53] S. Elmaghraby, Activity networks: Project planning and control by network models, New York: Wiley, 1977.
[54] C.-H. Chu and Y.-C. Chu, "Computerized ABC analysis: the basis for inventory management," vol. 13, no. 1-4, pp. 66-70, 13 1987.
[55] J. van den Akker, J. Vries and J. Wijngaard, "Complexity and uncertainty of materials procurement in assembly situation," International Journal of Production and Economics, pp. 137-152, 1996.
[56] S. Nof, W. Wilhelm and H.-J. Warnecke, Industrial Assembly, London: Chapman & Hall, 1997.
[57] R. Kolisch, "Integrated scheduling, assembly area- and part assignment for large-scale, make-to-order assemblies," International Journal of Production Economics, pp. 127-141, 2000.
[58] J. Lee, K. Lee, H. Park, J. H. Hong and J. Lee, "Developing schedling systems for Daewoo shipbuilding: DAS project.," European Journal of Operational Research, pp. 168-187, 1997.
[59] J. Moder, C. Phillips and E. Davis, Project Management with CPM, PERT and precedence programming, New York: Van Nostrand Reinhold, 1983.
[60] R. Kolisch and A. Drexl, "Assembly management in machine tool manufacturing and the PRISMA-Leitstand," Production and Inventory Management Journal, pp. 55-57, 1996.
[61] J. Blazewicz, J. Lenstra and A. Rinnoy Kan, "Scheduling subject to resource constraints: Classification and complexity," Discrete Applied Mathematics, pp. 11-24, 1983.
[62] A. Pritsker, L. Watters and P. Wolfe, "Multiproject scheduling with limited resource: A zero-one programming approach," Management Science, pp. 93-107, 1969.
[63] P. Brucker, A. Drexl, R. Möhring, K. Neumann and E. Pesch, "Resource-constrained project scheduling: Notation, classification, models and methods," European Jouranl of Operational Research, pp. 3-41, 1999.
[64] R. Graham, E. Lawler, J. Lenstra and A. Rinnoy Kan, "Optimization and approximation in deterministic sequencing and scheduling: a survey," Annals of Discrete Mathematics, pp. 236-287, 1979.
[65] W. Herroelen, B. Reyck and E. Demeulemeester, "Resource-constrained project scheduling: A survey of recent developments," Computers & Operations Research, pp. 279-302, April 1998.
[66] R. Padman, „Early-tardy cost trade-offs in resource constrained projects with cash flows: An optimization-guided heuristic approach,“ European Journal of Operational Research, Bd. 64, pp. 295-311, 1993.
[67] R. Slowinski, B. Soniewicki and J. Weglarz, "DSS for multi-objective project scheduling," European Journal of Operational Research, vol. 79, pp. 220-229, 1994.
[68] R. Kolisch, A. Sprecher and A. Drexl, "Characterization and Generation of a General Class of Resource-Constrained Project Scheduling Problems," Management Science, vol. 41, no. 10, pp. 1693-1703, 1995.
[69] B. De Reyck and W. Herroelen, "The multi-mode resource-constrained project scheduling problem with generalized precedence relations," European Journal of Operational Research, vol. 119, pp. 538-556, 1999.
[70] C. Artigues and F. Roubellat, "A polynomial activity insertion algorithm in a multi-resource schedule with cumulative constraints and multiple modes," European Journal of Operational Research, vol. 127, pp. 297-316, 2000.
[71] U. Dorndorf, E. Pesch and T. Phan-Huy, "A Time-Oriented Branch-and-Bound Algorithm for Resource-Constrained Project Scheduling with Generalized Precedence Constraints," Management Science, vol. 46, no. 10, pp. 1365-1384, 2000.
[72] B. Frank, K. Neumann and C. Schwindt, "Truncated branch-and-bound, schedule construction, and schedule improvement procedures for resource-constrained project scheduling," OR Spektrum, vol. 23, pp. 297-324, 2001.
[73] K. Nonobe and T. Ibaraki, "Formulation and Tabu Search Algorithm for the Resource Constrained Project Scheduling Problem," Essays and Surveys in Metaheuristics, pp. 557-588, 2002.
[74] D. Merkle, M. Middendorf and H. Schmeck, "Ant Colony Optimization for Resource-Constrained Project Scheduling," Transactions on Evolutionary computation, vol. 6, no. 4, pp. 333-346, 2002.
[75] K. Bouleimen and H. Lecocq, "A new efficient simulated annealing algorithm for the resource-constrained project scheduling problem and its multiple mode version," European Journal of Operational Research, vol. 149, pp. 268-281, 2003.
[76] K. Fleszar and K. S. Hindi, "Solving the resource-constrained project scheduling problem by a variable neighborhood search," European Journal of Operational Research, vol. 155, pp. 402-413, 2004.
[77] X. Zhu and W. E. Wilhelm, "Three-stage approaches for optimizing some variations of the resource constrained shortes-path sub-problem in a column generation context," European Journal of Operational Research, vol. 183, pp. 564-577, 2007.
[78] J. Mendes, J. F. Goncalves and M. Resende, "A random key based genetic algorithm for the resource constrained project scheduling problem," Computers & Operations Research, vol. 36, pp. 92-109, 2007.
[79] V. Valls, F. Ballestin and S. Quintanilla, "A hybrid genetic algorithm for the resource-constrained project scheduling problem," European Journal of Operational Research, vol. 185, pp. 495-508, 2008.
[80] P.-H. Chen and S. M. Shahandashti, "Hybrid of genetic algorithm and simulated annealing for multiple project scheduling with multiple resource constraints," Automation in Construction, vol. 18, pp. 434-443, 2009.
[81] V. V. Peteghem and M. M Vanhoucke, "A genetic algorithm for the preemptive and non-preemptive multi-mode resource-constrained project scheduling problem," European Journal of Operational Research, vol. 201, pp. 409-419, 2010.
[82] S. Elloumi and P. Fortemps, "A hybrid rank-based evolutionar algorithm applied to multi-mode resource-constrained project scheduling problem," European Journal of Operational Research, vol. 205, pp. 31-41, 2010.
[83] T. R. Browning and A. A. Yassine, "Resource-constrained multi-project scheduling: Priority rule performance revisited," International Journal Production Economics, vol. 126, pp. 212-228, 2010.
[84] M. Ranjbar, S. Hosseinabadi and F. Abasian, "Minimizing total weighted late work in the resource-constrained project scheduling problem," Applied Mathematical Modelling, vol. 37, pp. 9776-9785, 2013.
[85] H. C. Gomes, F. d. A. Neves and M. J. F. Souza, "Multi-objective metaheuristic algorithms for the resource-constrained project schedulung problem with precedence relations," Computers & Operations Research, vol. 44, pp. 92-104, 2014.
[86] A. Delgoshaei, M. K. Mohd Ariffin, B. Baharudin and Z. Leman, "Minimizing makespan of a resource-constrained scheduling problem: A hybrid greedy and genetic algorithm," International Journal of Industrial Engineering Computations, vol. 6, 2015.
[87] A. Viana and J. Pinho de Sousa, "Using metaheuristics in multi-objective resource constrained project scheduling," Europen Journal of Operational Research, vol. 120, pp. 359-374, 2000.
[88] J. Buddhakulsomsiri and D. S. Kim, "Priority rule-based heuristic for multi-mode resource-constrained project scheduling problems with resource vacations and activity splitting," European Journal of Operational Research, vol. 178, pp. 374-390, 2007.
[89] D. Lin-yia and L. Yanb, "Particle swarm optimization for resource-constrained project scheduling problems with activity splitting," Control and Decision, 2008.
[90] H.-P. Kao, B. Hsieh and Y. Yeh, "A Petri-Net Based Approach for Scheduling and Rescheduling Resource-Constrained Multiple Projects," Journal of the Chinese Institute of Industrial Engineers, vol. 23, no. 6, pp. 468-477, 206.
[91] R. Kolisch and S. Hartmann, "Heuristic Algorithms for the Resource-Constrained Project Scheduling Problem: Classification and Computational Analysis," International Seires in Operation Research & Management Scince, vol. 14, pp. 147-178, 1999.
[92] R. Kolisch and S. Hartmann, "Experimental investigations of heuristics for resource-constrained project scheduling: An update," European Journal of Operational Research, vol. 147, no. 1, pp. 23-37, 2006.