Production Planning and Scheduling in Flexible Assembly Systems

Finally,specificissuesinplanningandschedulingofPCBassem­ blyarediscussed. VIII Preface InChapter3variousbi-objectiveintegerprogrammingmodelsandso­ lutionapproachesarepresentedformachineloadingandassembly-routing inFASs. Aninteractiveprocedureisproposedforsimultaneousloadingand routingbasedonweightingapproachandalexicographicalgorithmisgiven forsequentialloadingandroutingwithalinearrelaxationloadingheuristic andanetworkflowroutingmodel. Numericalexamplesillustratepossible applicationsofthemodellingandsolutionapproachespresented. InChapter4thesequentialmodellingandsolutionapproachproposedin Chapter3hasbeenextendedforabicriterionmachineloadingandassembly routingwithsimultaneousassemblyplanselectioninageneralFASandina flexibleassemblyline. Numericalexamplesareprovidedtoillustratepossible applicationsoftheapproachproposed. Chapter5presentsmathematicalprogrammingformulationsforsimul­ taneousloadingandschedulinginflexibleassemblycells. Theformulations areillustratedwithpracticalapplicationsinmechanicalpartassemblywith arobotassemblycellandinPCBassemblyonacomponentplacementma­ chine. Chapter6isdevotedtoproductionschedulinginflexibleassemblylines whereseveralassemblystagesinseriesareeitherseparatedbyfiniteinter­ mediatebuffersortherearenobuffersbetweenthestages,andeachstage consistsofoneormoreidenticalparallelmachines. Fastpush-typeschedul­ ingheuristicsareproposedforthelinewithlimitedintermediatebuffersor thelinewithnoin-processbuffers. Foracomparison,apull-typeschedul­ ingstrategyisillustratedwithsomerecentresultsfortheJust-In-Timeand multilevelschedulingofflexibleassemblylines. Numericalexamplesprovide thereaderwithpossibleapplicationsofthevariousmodellingandsolution approachespresented. InChapter7simultaneousschedulingofassemblystationsandautomated guidedvehiclesisdiscussedforageneralFASandtwodifferentsolutionap­ proachesarepresented:(i)amulti-levelapproach,inwhichfirstmachine loadingandassemblyroutingproblemissolvedandthen,giventaskassign­ mentsandassemblyroutesselected,detailedmachineandvehicleschedules aredetermined;(ii)asingle-levelapproach,inwhichmachineandvehicle schedulesaredirectlydeterminedwithnoinitialloadingandroutingdeci­ sionsrequired. Foreachapproachaschedulingalgorithmbasedondynamic complexdispatchingrulesisproposedandnumericalexamplesareprovided toillustrateandcomparethetwoschedulingapproaches. Thematerialpresentedinthebookisillustratedwithnumerousexamples, figuresandextensivetables. Thereaderisprovidedwithdetailedmathemat­ icalmodelsoftheFASplanningandschedulingproblemsanddescriptions ofthesolutionalgorithmsproposed. Theirapplicationsareillustratedwith manynumericalexamplesandresultsofvariouscomputationalexperiments withthemodelsandalgorithmsarereported. Preface IX Thebookisaimedprimarilyatstudentsandprofessionalsinproduction andoperationsmanagement,industrialandsystemsengineering,andauto­ matedmanufacturing. Thisbookbenefitedfromnumerousdiscussionswithmycolleagues. Pro­ fessorAndreasDrexlandDr. RainerKolischfromtheChristian-Albrechts UniversityofKieldeservespecialthanksforthecarefulreadingofvarious partsofthemanuscriptandtheirvaluablecomments. ThebookhasbeenpreparedwithpartialsupportbyKBNresearchgrant #8TllF01513,AGHgrant#10. 200. 10,andTEMPUS-PHAREproject #S_JEP-09434-95. TadeuszSawik DepartmentofComputerIntegratedManufacturing FacultyofManagement UniversityofMiningandMetallurgy Krakow,Poland TableofContents 1. FlexibleAssemblySystems-HardwareComponentsand Features. 1 1. 1 BasiccomponentsofaFAS. 1 1. 1. 1Robots. 1 1. 1. 2 PeripheraJequipment. 4 1. 2 Classificationof'flexibleassemblysystems 5 1. 3 Examplesofindustrialinstallations. 8 1. 3. 1 Mechanicalassembly. 8 1. 3. 2 Printedcircuitboardassembly. 9 2. IssuesinDesign,PlanningandSchedulingofFlexible Assembly. 17 2. 1 FASdesignissues. 18 2. 2 Networkdesignformaterialflowsystems. 22 2. 3 Designforassembly. 27 2. 4 Assemblyplanning 30 2. 5 Planningandscheduling. 32 2. 5. 1 Machineloadingandassemblyrouting. 35 2. 5. 2 Machineandvehiclescheduling 37 2. 5. 3 Planningandschedulinginelectronicsassembly. 38 3. LoadingandRoutingDecisionsinFlexibleAssembly Systems 41 3. 1 Descriptionofaflexibleassemblysystem. 43 3. 2 Optimizationofstationworkloadsandproductmovements. 44 3. 3 Designandbalancingofflexibleassemblylines. 50 3. 4 Numericalexamples 52 3. 5 Simultaneousloadingandrouting 56 3. 5. 1 Problemformulations. 56 3. 5. 2 Aninteractiveheuristicforloadingandrouting 60 3. 5. 3 Numericalexamples. 61 3. 6 Sequentialloadingandrouting. 68 3. 6. 1 Problemformulations.