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Research Papers

Assembly System Reconfiguration Planning

[+] Author and Article Information
April Bryan

e-mail: abryan@umich.edu

Yoram Koren

Department of Mechanical Engineering,
University of Michigan,
Ann Arbor, MI 48109

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received August 3, 2011; final manuscript received March 29, 2013; published online July 17, 2013. Assoc. Editor: Wei Li.

J. Manuf. Sci. Eng 135(4), 041005 (Jul 17, 2013) (13 pages) Paper No: MANU-11-1267; doi: 10.1115/1.4024288 History: Received August 03, 2011; Revised March 29, 2013

Decreasing product life cycles and reduced product development times have led to a need for new strategies for coping with the rapid rate of product family design changes. In this paper, assembly system reconfiguration planning (ASRP) is introduced as a method for cost effectively designing several generations of assembly systems in order to produce a product family that gradually evolves over time. In the ASRP approach, the possible assembly systems for each generation are first considered and then the sequence of assembly system configurations that minimize the life cycle cost of the process are selected. A nonlinear integer optimization formulation is developed for finding the cost minimizing assembly system reconfiguration plan using the ASRP approach. Dynamic programming and genetic algorithm are used to solve the optimization problem. Simulation results indicate that the ASRP approach leads to the minimum life cycle costs of the assembly system, and the relative cost of reconfiguration and production have an impact on the assembly system reconfiguration plan selected. Comparison of the results of the dynamic program and genetic algorithm indicate that the dynamic program is more computationally efficient for small problems and genetic algorithm is preferred for larger problems.

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Figures

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Fig. 1

Multigeneration product family precedence diagram

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Fig. 2

Assembly system representation

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Fig. 3

Life cycle of an assembly system

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Fig. 4

Staged network of assembly system configurations

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Fig. 5

Sequence of q items with p partitions

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Fig. 6

Partitioning algorithm

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Fig. 7

All possible assembly system layouts for three centers

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Fig. 8

Chromosome encoding

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Fig. 9

Example 1 multigenerational precedence diagram

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Fig. 10

Example 1 assembly plan using ASRP

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Fig. 11

Example 1 assembly plans using generation by generation

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Fig. 12

Example 1 configurations for given reconfiguration factors

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Fig. 13

Example 2 multigenerational precedence diagram

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