• Journal of Korean Society of Industrial and Systems Engineering
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• v.37 no.2
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• pp.1-8
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• 2014

The automobile manufacture is a typical integrated assembly production that the numerous parts are committed sequentially to the assembly line. In this type of automobile manufacture, WBS (white body storage) and PBS (paint body storage) are operated to adjust the production sequence and to buffer. Starvation (impossibility of production owing to the insufficient supply) or blocking (impossibility of production owing to the over capacity) could occur in some chance, hence, both storages (WBS, PBS) are integrated as a prevention. This system is called integrated storage. In this paper, we suggest the simulation model of 'WBS-PBS integrated storage' and methodology of operation considering both 'Color grouping' and 'Option leveling.'

• Proceedings of the Korean Operations and Management Science Society Conference
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• 2004.05a
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• pp.425-428
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• 2004

Flexible assembly line (FAL) is a production system that assembles various parts in unidirectional flow line with many constraints and manufacturing flexibilities. In this research we deal with a FAL balancing problem with the objective of minimizing the maximum workload allocated to the stations. However, almost all the existing researches do not appropriately consider various constraints due to the problem complexity. Therefore, this thesis addresses a balancing problem of FAL with many constraints and manufacturing flexibilities, unlike the previous researches. To solve this problem we use a genetic algorithm (GA). To apply GA to FAL, we suggest a genetic representation suitable for FAL balancing and devise evaluation method for individual's fitness and genetic operators specific to the problem, including efficient repair method for preserving solution feasibility. The experimental results are reported.

• Journal of the Korean Society of Industry Convergence
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• v.13 no.2
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• pp.107-112
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• 2010

The automation and Cell-Line of manufacturing process are going to be new trend in the industry spot. But workers bodily burden by manual labour is still doing repeatedly at many processes. It is appearing to workers bodily burden (Shoulder, waist, hand, wrist, leg) with repeating works at assembly line which is from the static working space. The analysis with 6 Sigma Tool at specific standard assembly line improve the point at issue for unsuitable items and analyzed objects. Physical pain of worker is solved by the improvement action for the factor of 7 items with the result of analysis. It was known to be improved by solving of workers burden related to the change of 6 Sigma level from 2.16 to 4.1 at assembly line.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.30 no.3
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• pp.89-93
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• 2007

In this study, we consider an assembly line operated under a base-stock policy. A product consists of two parts, and a finished product transfers to a warehouse in which demands are satisfied. Assume that demands arrive according to a Poisson process and processing times at each production line are exponentially distributed. Whenever a demand arrives, it is satisfied immediately from an inventory in the warehouse if available; otherwise, it is backlogged and satisfied later by the next product exiting from production lines. In either case, an arriving demand automatically triggers the production of a part at both production lines. These two parts will be assembled into a product that eventually transfers to the warehouse. We obtain a closed form formula of approximation for delay time or lead time distribution of a demand when a base- stock level is s. Moreover, it can be applied to the optimal base-stock level which minimizes the total inventory cost. Numerical examples are presented to show our optimal base-stock level's quality.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.16 no.1
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• pp.124-133
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• 2017

In the current lighting market, LEDs that have a high luminous efficiency, a long life and consume less power have emerged as next generation lighting. Owing to various designs and sizes of LEDs, the production process of existing LEDs involves many tasks that require manual labor; hence, the assembly of LEDs necessitates manpower. Because of the use of manpower, the production costs of LEDs increases and production efficiency decreases. Recently, the assembly parts of LEDs have been standardized for minimizing manual labor, and an LED is developed as an LED panel. The automatic assembly system produces LED convergent lighting by assembling two LED panels and one diffusion cover. To increase the production efficiency of the LED convergent lighting module, it is important that the development of a feeder can continuously supply the LED panels is required, and whose design has sufficient stability. The automatic assembly system of the LED convergent lighting module consists of two feeders, which convey LED panels and diffusion covers to a main conveyor, which assembles the lifted panels and covers. In this study, structural analysis and fatigue life for forced loads on the conveyer line of the feeder in the process of lifting LED panels and diffusion covers of each feeder, is analyzed. In addition, the drive of the belt constituting the conveyor line of each feeder is simulated, and the dynamic characteristics of the belt is analyzed using the virtual engineering method.

• Industrial Engineering and Management Systems
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• v.4 no.1
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• pp.36-46
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• 2005

In traditional production lines, such as assembly lines, each worker is usually assigned to a fixed task, which is beneficial since it reduces the amount of training needed for workers to master their assigned tasks. However, when workers complete their tasks at different speeds, the slowest worker will determine the overall pace of the production line and limit production. To avoid this problem, the self-balancing production line was introduced. In this type of production line, each worker works dynamically, thus they can maintain balanced production. Previous research analyzing the performance of these lines has ignored the walk-back time associated with dynamic workers. U-shaped production lines have also been analyzed and policies for such lines have been proposed. However, the walk-back time cannot be ignored in practice, and research taking this factor into account is needed to enable balanced production and thus the maximum production rate. In this paper, we propose production policies for a production line with the walk-back time taken into account, and define and analyze the conditions for self-balancing. Furthermore, we have compared the performance of such a line with that of other production lines under the same conditions, and the results show the superiority of this line in certain cases.

• Journal of Korean Institute of Industrial Engineers
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• v.35 no.1
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• pp.15-39
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• 2009

Advanced planning and scheduling (APS) refers to a manufacturing management process by which raw materials and production capacity are optimally allocated to meet demand. APS is especially well-suited to environments where simpler planning methods cannot adequately address complex trade-offs between competing priorities. However, most scheduling problems of APS in the real world face both inevitable constraints such as due date, capability, transportation cost, set up cost and available resources. In this survey paper, we address three crucial issues in APS, including basic scheduling model, job-shop scheduling (JSP), assembly line balancing (ALB) model, and integrated scheduling models for manufacturing and logistics. Several evolutionary algorithms which adapt to the problems are surveyed and proposed; some test instances based on the practical problems demonstrate the effectiveness and efficiency of evolutionary approaches.

• Journal of the Korean Operations Research and Management Science Society
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• v.26 no.4
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• pp.109-124
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• 2001

This paper presents a new method that can efficiently solve the integrated problem of line balancing and model sequencing in mixed model assembly lines (MMALs). Line balancing and model sequencing are important for an efficient use of MMALs. The two problems of balancing and sequencing MMALs are tightly related with each other. However, In almost all the existing researches on mixed-model production lines, the two problems have been considered separately. In this research, an endosymbiotic evolutionary a1gorithm, which is a kind of coevolutionary a1gorithm, is adopted as a methodology in order to solve the two problems simultaneously. This paper shows how to apply an endosymbiotic evolutionary a1gorithm to solving the integrated problem. Some evolutionary schemes are used In the a1gorithm to promote population diversity and search efficiency. The proposed a1gorithm is compared with the existing evolutionary algorithms in terms of solution quality and convergence speed. The experimental results confirm the effectiveness of our approach.

• 제어로봇시스템학회:학술대회논문집
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• 1996.10b
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• pp.1237-1240
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• 1996

This paper proposes a heuristic algorithm for performing the line balancing of PCB assembly fine including multiple surface mounters efficiently. We consider a PCB assembly line including the multiple surface mounters arranged serially as a target system. We assume that the number of heads of surface mounters can be changed. Also, the conveyor is assumed to move at a constant speed and have no buffer. Considering the minimum number of machines required for the desired production rate is a discrete nonincreasing function which is inversely proportional to the cycle time, we propose an optimization algorithm for line balancing by using the binary search method. Also we propose an head-changing algorithm. The algorithms are validated through the computer simulation.

• Proceedings of the Korea Society for Simulation Conference
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• 1999.04a
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• pp.105-109
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• 1999

Tool shop of the D Heavy Industries Co.(DHI) fabricates engines for a bus, truck, small ship. In order to increase the production capacity of engines, DHI will be established the new tool shop that consists of a block line, head line, assembly line, test line and AS/RS in 1999. In order to assure the production capacity designed of the new tool shop for producing engines and improve the production process of it, it is needed to find a bottleneck process and an optimal way of allocating workloads among machines and workers to maximize the production. In a way to solve this, we model the engine fabrication process of the tool shop and analyze its performance by computer simulation. In this study, we at first identify the bottleneck processes of the engine fabrication process under the designed operation policy. Then, we derive some alternative operating policies applicable to the new tool shop of an engine, and analyze the optimal operation policy by comparing the performance of the tool shop following each alternative policy.