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Floater Allocation in Paced Mixed Model Assembly Lines: Design and implementation of a method for operational scheduling of cross-trained workers in Mixed-Model Assembly Lines

Overbeek, T.A.G. van (2015) Floater Allocation in Paced Mixed Model Assembly Lines: Design and implementation of a method for operational scheduling of cross-trained workers in Mixed-Model Assembly Lines.

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Abstract:Car producer ‘Company A’ uses a Paced Mixed Model Assembly Line (MMAL) for their final assembly. Different configurations and models of cars are produced, resulting in varying workloads for stations. To resolve overload situations, cross-trained workers ('floaters') are used that that assist regular workers in case of overload situations. Currently, floaters are deployed reactively at Company A. Smart scheduling of these floaters will increase their effectiveness. Therefore, the goal of this research is to develop a tool for the operational scheduling of floaters in the assembly line of Company A, with the goal of minimizing overload situations. Overload situations are measured by overtime (unfished workload) and defects (number of overtime occurrences). The proposed solution method works by first creating an initial solution (schedule) using Parallel First Come First Serve. Then, problematic parts of the floater schedule (partial schedules) are selected using a Guidance Rule. The partial schedule is then optimized using Simulated Annealing, and inserted back in the main schedule. This process is performed iteratively. The solution was implemented and optimal parameters were determined. For the total assembly line, an average reduction in overtime and defects of 84% and 79% respectively was achieved compared to the current way of working.
Item Type:Essay (Master)
Clients:
Ergo-Design B.V., Enschede, Netherlands
Faculty:BMS: Behavioural, Management and Social Sciences
Subject:54 computer science, 83 economics, 85 business administration, organizational science
Programme:Industrial Engineering and Management MSc (60029)
Link to this item:http://purl.utwente.nl/essays/68920
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