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TECHNICAL PAPERS

Concurrent Optimization of Product Module Selection and Assembly Line Configuration: A Multi-Objective Approach

[+] Author and Article Information
Zhonghui Xu

Department of Mechanical Engineering,  University of Ottawa, 770 King Edward Avenue, Ottawa, ON K1N 6N5, Canada

Ming Liang1

Department of Mechanical Engineering,  University of Ottawa, 770 King Edward Avenue, Ottawa, ON K1N 6N5, Canadaliang@eng.uottawa.ca

1

To whom correspondence should be addressed.

J. Manuf. Sci. Eng 127(4), 875-884 (Mar 27, 2005) (10 pages) doi:10.1115/1.2034513 History: Received August 26, 2004; Revised March 27, 2005

Both modular product design and reconfigurable manufacturing have a great potential to enhance responsiveness to market changes and to reduce production cost. However, the two issues have thus far mostly been investigated separately, thereby causing possible mismatch between the modular product structure and the manufacturing or assembly system. Therefore, the potential benefits of product modularity may not be materialized due to such mismatch. For this reason, this paper presents a concurrent approach to the product module selection and assembly line design problems to provide a set of harmonic solutions to the two problems and hence avoid the mismatch between design and manufacturing. The integrated nature of the problem leads to several noncommensurable and often conflicting objectives. The modified Chebyshev goal programming approach is applied to solve the multi-objective problem. A genetic algorithm is further developed to provide quick and near-optimum solutions. The proposed approach and the solution procedure have been applied to an ABS motor problem. The performance of the genetic algorithm has also been examined.

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Copyright © 2005 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Product modules and product variants

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Figure 2

A precedence diagram

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Figure 3

An assembly line configuration for a modular product

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Figure 4

Two instances of a cover-base module

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Figure 5

An example of chromosome coding

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Figure 6

Precedence diagram and precedence matrix

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Figure 7

Illustration of crossover operations

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Figure 8

Mutation operation

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Figure 9

ABS motor modules

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Figure 10

Line balancing results

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Figure 11

Convergence of δ and evolution processes of individual objectives

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