An automated multi criteria assembly line design generation method for decision making support: an automotive case study

Abstract

The objective of the present study is the development of a method for the automated design of assembly lines using a multiple criteria approach. This method aims at supporting the decision making process during the early design stages as well as during the reconfiguration stages of assembly lines. Towards this target, a complete approach is proposed investigating the aspects of the design problem in both human and automation based assembly lines. At first, the current practices for design /reconfiguration of automated/ human based assembly lines were analysed and the decision making process was modelled in each case. Following the design problem was formulated in a way that allows its solution by the use of search algorithms which are easier and more efficient to apply. Models capable of systematically generating the alternative assembly lines designs were designed and implemented. An intelligent search algorithm was applied to these models allowing the efficient exploration of the design problem solution space and the fast identification of high quality design solutions with respect to several user defined criteria (such as investment cost, flexibility etc.). All the aforementioned were incorporated into two distinct software tools, having as objective the support of assembly line design and reconfiguration. The first tool incorporates the design model and algorithms in a standalone application that can automatically generate, simulate and evaluate alternative assembly lines designs based on the product structure and the available equipment and processes. The second tool was developed as a web based application that allows the reconfiguration of human based assembly lines through the concept of dynamic job rotation. The tool is able to derive alternative rotation schedules and evaluate them against criteria that are used for the case of human based assembly lines. The main outcome of this work is the complete method that was proposed and realized through software tools, which is capable of providing solutions for the design and reconfiguration of assembly lines. The method can assist design engineers in real time through the automated generation, evaluation and identification of high quality design alternatives. The evaluation of the case studies revealed the efficiency of the suggested approach to produce such designs and validated its applicability to industrial environments.