Abstract
We present a rough-cut analysis tool that quickly determines a few potential cost-effective designs at the initial design stage of flexible assembly systems (FASs) prior to a detailed analysis such as simulation. It uses quantitative methods for selecting and configuring the components of an FAS suitable for medium to high volumes of several similar products. The system is organized as a series of assembly stations linked with an automated material-handling system moving parts in a unidirectional flow. Each station consists of a single machine or of identical parallel machines. The methods exploit the ability of flexible hardware to switch almost instantaneously from product to product. Our approach is particularly suitable where the product mix is expected to be stable, since we combine the hardware-configuration phase with the task-allocation phase.
For the required volume of products, we use integer programming to select the number of stations and the number of machines at each station and to allocate tasks to stations. We use queueing network analysis, which takes into account the mean and variance of processing times among different products to determine the necessary capacity of the material-handling system. We iterate between the two analyses to find the combined solution with the lowest costs. Work-in-process costs are also included in the analysis. Computational results are presented.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
AkellaR., SinghM., and BassokY., “Real Time Part Dispatch in Flexible Assembly Test and Manufacturing Systems,” Technical Report, Graduate School of Industrial Administration, Carnegie Mellon University, Pittsburgh, PA (1988).
AmmonsJ.C., LofgrenC.B., and McGinnisL.F., “A Large Scale Machine Loading Problem in Flexible Assembly,” Annals of Operations Research, Vol. 3, pp. 319–332 (1985).
BaybarsI., “A Survey of Exact Algorithms for the Simple Assembly Line Balancing Problem,” Management Science, Vol. 32, No. 8, pp. 909–932 (August 1986).
BerradaM. and SteckeK.E., “A Branch and Bound approach for Machine Load Balancing in Flexible Manufacturing Systems,” Management Science, Vol. 32, No. 10, pp. 1316–1335 (October 1986).
BoothroydG., PoliC., and MurchL., Automatic Assembly, Marcel Dekker, New York, NY (1982).
BrowneJ., ChanW., and RathmillK., “An Integrated FMS Design Procedure,” Annals of Operations Research, Vol. 3, pp. 207–237 (1985).
BulgakA. and SandersJ., “Hybrid Algorithms for Design Optimization of Asynchronous Flexible Assembly Systems with Statistical Process Control and Repair,” Proceedings of the 3rd ORSA/TIMS Conference on Flexible Manufacturing Systems, M.I.T., Cambridge, MA. K.Stecke and R.Suri (Eds.), Elsevier Science Publishers B.V., Amsterdam, pp. 275–280 (August 1989).
BuzenJ.P., “Computational Algorithms for Closed Queueing Networks with Exponential Servers,” Communications of the Association of Computing Machinery, Vol. 16, No. 9, pp. 527–531 (1973).
DalleryY. and FreinY., “An Efficient Method to Determine the Optimal Configuration of a Flexible Manufacturing System,” Proceedings of the 2nd ORSA/TIMS Conference on Flexible Manufacturing Systems, Ann Arbor, MI, K.Stecke and R.Suri (Eds.), Elsevier Science Publishers B.V., Amsterdam, pp. 269–282 (August 1986).
DalleryY. and SteckeK., “On the Optimal Allocation of Servers and Workloads in Closed Queueing Networks,” Operations Research, Vol. 38, No. 4, pp. 694–703 (July–August 1990).
DenningP. and BuzenJ., “The Operational Analysis of Queueing Network Models,” Association of Computing Machinery Computing Surveys, Vol. 10, No. 3, pp. 225–261 (1978).
GershwinS., AkellaR., and ChoongY., “Short-term Production Scheduling of an Automated Manufacturing Facility,” Annals of Operations Research, Vol. 3, pp. 392–400 (1985).
GrahamG.S., “Queueing Network Models of Computer System Performances,” Computing Surveys, Vol. 10, No. 3, pp. 219–224 (1978).
GravesS.C. and RedfieldC.H., “Equipment Selection and Task Assignment for Multiproduct Assembly System Design,” International Journal of Flexible Manufacturing Systems, Vol. 1, No. 1, pp. 31–50 (September 1988).
GrooverM., WeissM., NagelR., and OdreyN. Industrial Robotics, McGraw-Hill, New York, NY (1986).
HallD.N. and SteckeK.E., “Design Problems of Flexible Assembly Systems,” Proceedings of the 2nd ORSA/TIMS Conference on Flexible Manufacturing Systems, Ann Arbor, MI, K.Stecke and R.Suri (Eds.), Elsevier Science Publishers B.V., Amsterdam, pp. 145–156 (August 1986).
Hildebrant, R., “Scheduling Flexible Machining Systems Using Mean Value Analysis,” Proceedings of the IEEE Conference on Decision and Control, IEEE, New York, pp. 701–706 (December 1981).
HitzK., “Flexible Integrated Computer-aided Manufacturing Systems Increase Productivity,” Robotics and Computer-Intergrated Manufacturing, Vol. 3, No. 1, pp. 123–128 (1987).
HoY., SuriR., CaoX., DiehlG., DilleJ., and ZazanisM., “Optimization of Large Multiclass (Non-product-form) Queueing Networks Using Perturbation Analysis,” Large Scale Systems, Vol. 7, pp. 1–16 (1984).
JohnsonR.V., “Optimally Balancing Large Assembly Lines with ‘FABLE’,” Management Science, Vol. 34, No. 2, pp. 240–253 (February 1988).
KamathM., SuriR., and SandersJ., “Analytical Performance Models for Closed-Loop Flexible Assembly Systems,” International Journal of Flexible Manufacturing Systems, Vol. 1, No. 1, pp. 51–84 (September 1988).
KilbridgeM. and WesterL.,” A Heuristic Method of Assembly Line Balancing,” Journal of-Industrial Engineering, Vol. 12, pp. 292–298 (1961).
KleinrockL., Queueing Systems II, John Wiley and Sons, New York, New York (1976).
LeeH.F., SrinivasanM.M., and YanoC.A., “Algorithms for the Minimun Cost Configuration Problem in Flexible Manufacturing Systems,” Proceedings of the 3rd ORSA/TIMS Conference on Flexible Manufacturing Systems, M.I.T., Cambridge, MA, K.Stecke and R.Suri (Eds.), Elsevier Science Publishers B.V., Amsterdam, pp. 85–90 (August 1989).
LiuC. and SandersJ., “Stochastic Design Optimization of Asynchronous Flexible Assembly Systems,” Proceedings of the 2nd ORSA/TIMS Conference on Flexible Manufacturing Systems, Ann Arbor, MI, K.Stecke and R.Suri (Eds.), Elsevier Science Publishers B.V., Amsterdam, pp. 191–202 (August 1986).
LiuC. and SandersJ., “Stochastic Design Optimization of Asynchronous Flexible Assembly Systems,” Annals of Operations Research, Vol. 15, pp. 131–154 (1988).
Muntz, R.R. and Wong, J.W., “Asymptotic Properties of Closed Queueing Network Models,” Proceedings of the 8th Annual Princeton Conference on Information Sciences and Systems, Princeton University, Princeton, New Jersey (1974).
OwenT., Flexible Assembly Systems, Plenum Press, New York (1984).
OwenT., Assembly with Robots, Prentice Hall, Englewood Cliffs, New Jersey (1985).
PosnerM. and BernholtzB., “Closed Finite Queueing Networks with Time Lags,” Operations Research, Vol. 16, No. 5, pp. 962–976 (September–October 1968).
Pourbabai, B., “Optimal Control of a Flexible Assembly System,” Proceedings of the 1987 ASME Design Technology Conference on Advances in Design Automation, Boston, MA, Vol. 1, pp. 335–337 (1987).
RankyP.G., “The Design of an End of Arm Tool Management System for Flexible Assembly Systems Utilizing Industrial Robots,” Report No. RSD-TR-21–86, Center for Research on Integrated Manufacturing, College of Engineering, The University of Michigan, Ann Arbor, Michigan (1986).
ReiserM. and LavenbergS., “Mean-Value Analysis of Closed Multichain Queueing Networks,” Journal of the Association for Computing Machinery, Vol. 27, No. 2, pp. 313–322 (1980).
Riley, F. and Yarrow, E., “A New Approach to Assembly Machine Justification,” Proceedings of the 2nd European Conference on Automated Manufacturing, Birmingham, U.K. (1983).
SawyerJ.F., Line Balancing, Machinery and Allied Products Institute, Washington, D.C. (1970).
SchrageL. and BakerK., “Dynamic Programming Solution of Sequencing Problems with Precedence Constraints,” Operations Research, Vol. 26, No. 3, pp. 444–459, (May–June 1978).
SeligerG. and WienekeB., “Analytical Approach for Function Oriented Production System Design,” Robotics and Computer-Integrated Manufacturing, Vol. 1, No. 3, pp. 307–313 (1984).
SeligerG., WiehwegerB., and WienekeB., “Descriptive Methods for Computer-Integrated Manufacturing and Assembly,” Robotics and Computer-Integrated Manufacturing, Vol. 3, No. 1, pp. 15–21 (1987a).
SeligerG., WiehwegerB., and WienekeB., “Decision Support in Design and Optimization of Flexible Automated Manufacturing and Assembly,” Robotics and Computer-Integrated Manufacturing, Vol. 3, No. 2, pp. 221–227 (1987b).
ShanthikumarJ.G. and SteckeK.E., “Reducing Work-in-Process Inventory in Certain Classes of Flexible Manufacturing Systems,” European Journal of Operational Research, Vol. 26, pp. 266–271 (1986).
ShanthikumarJ.G. and YaoD.D., “Optimal Server Allocation in a System of Multi-Server Stations,” Management Science, Vol. 33, No. 9, pp. 1173–1180 (September 1987).
ShanthikumarJ.G. and YaoD.D., “On Server Allocation in Multiple Center Manufacturing Systems,” Operations Research, Vol. 36, No. 2, pp. 333–342 (March–April 1988).
ShanthikumarJ.G. and YaoD.D., “Second-order Properties of the Throughput of a Closed Queueing Network,” Mathematics of Operations Research, Vol. 13, No. 3, pp. 524–534 (August 1988).
ShanthikumarJ.G. and YaoD.D., “Optimal Buffer Allocation in a Multicell System,” International Journal of Flexible Manufacturing Systems, Vol. 1, No. 4, pp. 347–356 (September 1989).
Solberg, J., “A Mathematical Model of Computerized Manufacturing Systems,” Proceedings of the 4th International Conference of Production Research, Tokyo, Japan (August 1977).
SpraginsJ., “Analytical Queueing Models: Guest Editor's Introduction,” IEEE Computer, Vol. 13, No. 4, pp. 9–11 (1980).
SpurG., FurgaeI., DeutschlanderA., BrowneJ., and O'GormanP., “Robot Planning System,” Robotics and Computer-Integrated Manufacturing, Vol. 2, No. 2, pp. 115–123 (1985).
SpurG., FurgacI., and KirchhoffU., “Robot System Integration into Computer-Integrated Manufacturing,” Robotics and Computer-Integrated Manufacturing, Vol. 3, No. 1, pp. 1–10 (1987).
SteckeK.E., “Formulation and Solution of Nonlinear Integer Production Problems for Flexible Manufacturing Systems,” Management Science, Vol. 29, No. 3, pp. 273–288 (March 1983).
SteckeK.E. and SolbergJ.J., “The Optimality of Unbalancing Both Workloads and Machine Group Sizes in Closed Queueing Networks of Multi-Server Queues,” Operations Research, Vol. 33, No. 4, pp. 882–910 (July–August 1985).
SuriR., “Robustness of Queueing Netwok Formulae,” Journal of the Association of Computing Machinery, Vol. 30, No. 3, pp. 564–594 (1983).
Suri, R. and Diehl, G., “MANUPLAN—a Precursor to Simulation for Complex Manufacturing Systems,” Proceedings of the Winter Simulation Conference (1985).
SuriR. and DiehlG., “Rough-Cut Modeling: An Alternative to Simulation,” CIM Review, Vol. 3, pp. 25–32 (1987).
TalbotF.B. and PattersonJ.H., “An Integer Programming Algorithm with Network Cuts Solving the Assembly Line Balancing Problem,” Management Science, Vol. 30, No. 1, pp. 85–99 (January 1984).
TalbotF.B., PattersonJ.H., and GehrleinW.V., “A Comparative Evaluation of Heuristic Line Balancing Techniques.” Management Science, Vol. 32, No. 4, pp. 430–454 (April 1986).
ThomopolousN.T., “Mixed-Model Line Balancing with Smoothed Station Assignments,” Management Science, Vol. 16, No. 9, pp. 593–603 (May 1970).
VinodB. and SabbaghM., “Optimal Performance Analysis of Manufacturing Systems Subject to Tool Availability,” European Journal of Operational Research, Vol. 24, pp. 398–409(1986).
VinodB. and SolbergJ., “The Optimal Design of Flexible Manufacturing Systems,” International Journal of Production Research, Vol. 23, No. 6, pp. 1141–1151 (1985).
WhitneyC.K. and SuriR., “Algorithms for Part and Machine Selection in Flexible Manufacturing Systems,” Annals of Operations Research, Vol. 3, pp. 239–261 (1985).
WhittW., “Open and Closed Models for Networks of Queues,” AT&T Bell Laboratories Technical Journal, Vol. 63, pp. 1911–1979 (1984).
WhittW., “The Best Order of Queues in Series,” Management Science, Vol. 31, No. 4, pp. 475–487 (April 1985).
YanoC.A., LeeH.F., and SrinivasanM.M., “Issues in the Design and Operation of Flexible Assembly Systems for Large Products: a Simulation Study,” Technical Report 88–10, Department of Industrial and Operations Engineering, University of Michigan, Ann Arbor, Michigan, to appear in Journal of Manufacturing Systems (1988).
YaoD.D. and BuzacottJ.A., “Queueing Models for a Flexible Machining Station, Part I: the Diffusion Approximation,” European Journal of Operational Research, Vol. 19, pp. 233–240 (1985).
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Lee, H.F., Johnson, R.V. A line-balancing strategy for designing flexible assembly systems. Int J Flex Manuf Syst 3, 91–120 (1991). https://doi.org/10.1007/BF00167513
Issue Date:
DOI: https://doi.org/10.1007/BF00167513