Cell staffing and standardized work design in Chaku-Chaku production lines using a hybrid optimization algorithm
Cell staffing and standardized work design in Chaku-Chaku production lines using a hybrid optimization algorithm
复制标题
使用混合优化算法在 Chaku-Chaku 生产线中进行单元人员配置和标准化工作设计
DOI：
10.1109/iccie.2009.5223901
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发表时间：
2009
期刊：
影响因子：
--
通讯作者：
J. Deuse
中科院分区：
文献类型：
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作者：
Wenming Zhang;J. Deuse
Chaku-Chaku生产线目前广泛应用于制造业和装配业，由于其灵活性以及以客户为导向的流程布局，它是一种有效和高效的生产组织类型。然而，由于客户需求的变化和不可预测的市场因素，布局和人力配置都面临着调整，以满足客户的订单，相比机器改造或重新设计新的生产线，调整的重点是转移到劳动力分配和工作重新分配，因为瓶颈资源的机器的利用率最多可以达到50%-60%。这项工作规定了计算生产线上的操作员人数和每个操作员的工作分配，即生产程序的标准化和每个操作员最佳标准化工作的设计。为了简化这类组合优化问题，将人力数量和详细工作分配分开，分别用混合线性规划模型（MILP）和约束规划模型（CP）描述，前者用于在多个内部约束条件下优化劳动力分配，后者用于实现详细调度，用于将具体工作分配给每个操作员，并进一步规范工作顺序和内容。该方法不考虑每个可行的操作序列，也不考虑相邻工人之间的协作，从而简化了指派问题，实现了最优劳动力的计算。结合CP模型，借助反馈回路，最终以甘特图的形式描绘出最优可行的标准化作业。该方法的性能也通过与现有文献中所述方法的比较进行了验证。
Chaku-Chaku production lines are currently widely adopted in manufacturing and assembly industry, which are an effective and efficient production organizational type thanks to its flexibility as well as customer-oriented flow layouts. However, due to the variation of customers' demand and unpredictable market factors, the layout as well as manpower allocation are both facing to be adjusted to satisfy the customers' orders, compared with reconstruction of machines or redesign of new production line, the adjusted focus is shifting to the workforce allocation and work reassignment, for the utilization of bottleneck resource machines can achieve at most 50%–60%. This work specifies the calculation of number of the operators employed to run the production line and work assignment for each operator, i.e. standardization of the production routines and the design of optimal standardized work for every operator. In order to simplify such combinatorial optimization problem, the number of manpower and the detailed work assignment are separated to be stated by Mixed Integer Linear Programming model (MILP) and Constraint Programming model (CP), the first model is used to optimize the workforce allocation subject to several internal constraints, the following model illustrates how to achieve the detailed scheduling, which is utilized to assign detailed work to each operator and further standardize the work sequence and content. MILP is constructed without consideration of each feasible operational sequence as well as cooperation between adjacent workers so as to simplify the assignment problem and then realize the calculation of optimal workforce. Combined with CP model as well as with the help of feedback loops, the optimal and feasible standardized work can be finally depicted in the form of Gantt chart. The performance of the approach is also verified through comparison with the stated approach in the currently available literature.