Sequencing and Sorting in Just-In-Time Production

Inhaltsverzeichnis (Table of Contents)

• Introduction.
• Problem Formulation and Simplification
• Simplification
• Splitting the Problem.
• History of the Subproblems
• Structure of this Work
• Notations
• Assembly Line Balancing.
• Objectives on Leveled Words.
• A Simplified Problem: Maximum Deviation Just-In-Time Scheduling
• A Model and an Integer Program
• Complexity Results
• NP-complete Cases
• Polynomial Cases
• Solution Approaches
• Exact Approaches.
• Heuristic Approaches
• Reduction of Color Changes.
• Previous Work
• Weak Balance of a Sequence
• A Model and an Integer Program
• Solution Approaches
• Exact Approaches.
• Heuristic Approaches
• Combining the Subproblems with the Buffer
• Theoretical Background
• Re-sorting the Paint Shop Sequence to an Assembly Sequence
• Re-sorting an Assembly Sequence to a Paint Shop Sequence
• Computational Results
• DISTANCE CONSTRAINED BALANCING
• WEAKLY BALANCED COLOR REDUCTION
• PS2AL versus AL2PS.
• Returning to Practice
• Basic Concepts
• Plant Layout
• Routing Patterns
• Rules.
• Sequence Construction
• Clustering into Slots
• Suggestions for Real World Production Plants
• Conclusions

Zielsetzung und Themenschwerpunkte (Objectives and Key Themes)

This work focuses on optimizing the production process in automobile manufacturing, specifically addressing the challenges of sequencing and sorting in just-in-time production. The primary aim is to improve efficiency by minimizing color changes in the paint shop while simultaneously ensuring the fulfillment of assembly shop requirements.

• Assembly line balancing and scheduling
• Color change reduction in the paint shop
• Buffer optimization for re-sorting car sequences
• Analysis of complexity and solution approaches for the subproblems
• Application of theoretical concepts to real-world production plants

Zusammenfassung der Kapitel (Chapter Summaries)

• Introduction: This chapter introduces the problem of sequencing and sorting in just-in-time production in the context of automobile manufacturing. It describes the different stages of production, including the body shop, paint shop, and assembly shop, and highlights the importance of minimizing color changes in the paint shop while meeting assembly shop requirements. The concept of a buffer as a re-sorting mechanism between the paint shop and assembly shop is introduced.
• Assembly Line Balancing: This chapter delves into the problem of assembly line balancing, specifically focusing on maximizing the deviation just-in-time scheduling. It presents a simplified model, an integer program, and analyzes the complexity of the problem. Different solution approaches, including exact and heuristic methods, are discussed.
• Reduction of Color Changes: This chapter focuses on minimizing color changes in the paint shop. It explores previous work on this topic, defines the concept of weak balance of a sequence, and presents a model and an integer program for the problem. Solution approaches, including exact and heuristic methods, are discussed.
• Combining the Subproblems with the Buffer: This chapter explores the capabilities of the buffer as a re-sorting mechanism. It provides a theoretical background, discusses the re-sorting processes from the paint shop to the assembly shop and vice versa, and combines the solution strategies from the previous chapters to address the overall problem.
• Computational Results: This chapter presents computational results for the different subproblems, including distance constrained balancing, weakly balanced color reduction, and comparisons between different re-sorting strategies.
• Returning to Practice: This chapter focuses on practical aspects of applying the theoretical concepts to real-world production plants. It covers basic concepts like plant layout, routing patterns, and rules, and discusses how to implement sequence construction and clustering in real-world scenarios. The chapter concludes with suggestions for optimizing production processes in real-world production plants.

Schlüsselwörter (Keywords)

Just-in-time production, assembly line balancing, color change reduction, buffer optimization, re-sorting, complexity analysis, solution approaches, computational results, plant layout, routing patterns, real-world applications.