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Aggregate Planning for Multi-product Assembly Lines with Reconfigurable Cells

Abstract:

This paper deals with aggregate planning of Reconfigurable Assembly Lines (RAL). The assembly line considered in this paper consists of hexagonal cells. These have multiple slots where processing modules can be inserted to perform certain operations. In addition, each cell has a single central slot where a central module can be inserted for inter-cellular and intra-cellular transportation of parts. Multiple products with different assembly sequences must be handled over multiple planning periods. An Integer Quadratic Programming (IQP) model is proposed to solve the following problems simultaneously: (i) assigning processing modules and a central module to the cells; (ii) installation of the cells and conveyors between the cells; and (iii) routing products, ensuring that availability of the resources is not exceeded. The assembly line should be reconfigured over time to adapt to possible product functionality and demand changes at minimum reconfiguration, operational and material handling costs while ensuring the demand is met within each period. The IQP model is implemented and solved for an illustrative problem and its extensions using Gurobi.