4.7 Article

Dynamic material flow control in mixed model assembly lines

Journal

COMPUTERS & INDUSTRIAL ENGINEERING
Volume 85, Issue -, Pages 110-119

Publisher

PERGAMON-ELSEVIER SCIENCE LTD
DOI: 10.1016/j.cie.2015.03.009

Keywords

Material flow; Milk run; Assembly lines; Disturbances; Dynamic planning; Resequencing

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This study investigates the control of material flow in mixed model assembly lines. It focuses on the use of tugger trains to feed stations in assembly lines by materials and parts from a warehouse or a supermarket. The movement of tugger trains is based on the principle of in-plant milk run. The study considers a strategy to deal with disturbances such as machine breakdown, line stoppage, defective parts, and resequencing of product models. These disturbances lead to unexpected fluctuations in stations demand for parts. The strategy is applied using a mix between the demand-oriented and e-kanban systems to facilitate the planning of three problems, namely, train routing, scheduling, and loading. The information obtained using e-kanban is combined with the information about the expected stations demand based on previously known sequence of product models and the materials needed for each model. Routing was investigated analytically while scheduling and loading problems were investigated using integer programming. Results showed that the method proposed outperforms the traditional methods of material flow planning. (C) 2015 Elsevier Ltd. All rights reserved.

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