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研究生:王龍偉
研究生(外文):Hutama Parwananta
論文名稱:分枝界線法求解製鞋業車縫線資源限制生產線平衡問題
論文名稱(外文):Branch and Bound Method for Solving Resource-Constrained Assembly Line Balancing Problem in Footwear Sewing Line
指導教授:王孔政王孔政引用關係陳建良陳建良引用關係Maria Anityasari
指導教授(外文):Kung-Jeng WangJames C. ChenMaria Anityasari
口試委員:王孔政陳建良Maria Anityasari
口試日期:2012-06-18
學位類別:碩士
校院名稱:國立臺灣科技大學
系所名稱:工業管理系
學門:商業及管理學門
學類:其他商業及管理學類
論文種類:學術論文
論文出版年:2012
畢業學年度:100
語文別:英文
論文頁數:55
外文關鍵詞:Assembly line designequipments and operators assignmenttwo-stage branch-and-bounddepth-first-search(DFS)heuristic proceduresoftware development.
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In this paper we observe the assembly line design problem in a sewing line of a shoe manufacturing company. Every time a production run of a new shoe style started, the optimum configuration of workstations and the equipments and operators assigned, needs to be designed. Moreover, every time a production target change occurred, a task is removed, a new task is introduced or a task parameter is modified, the line is will require a redesign process of the line. Multiplied by more than 100 lines that the company owned, the requirement will become very much frequent. Hence the need of a robust procedure to rapidly deliver an optimal line design, which their current procedure cannot manage effectively, is highly required by the company.
The assembly line design addressed is a generalization of SALBP-I which seeks to minimize the cost of generating workstation configuration for a given cycle time. We proposed a two stage branch-and-bound method as the optimization approach. In the first stage, the objective is to find the optimal task and equipment assignment to workstation. While in the second stage the workstations generated from the first stage is assigned to operators, with the objective to maximally utilize each operator hired. We use heuristic procedure constructed from the unique requirement of the addressed line, to develop the initial result which will serve as the upper bound and depth-first-search (DFS) branching result for both stage of the branch-and-bound algorithm. By doing so we successfully decrease the size of the enumeration tree thus make the algorithm faster. Furthermore we develop software with our proposed algorithm embedded to make it more applicable in the company.
The result shows that the developed algorithm and software outperform the manual procedure in term of optimal solution, speed, ease of repetitiveness, consistency and expertise and experience requirement. The branch-and-bound procedure shows significant improvement compared to the heuristic solution especially in the model which consist many tasks and has a complicated precedence diagram.
Chapter 1: Introduction 1
1.1. Background 1
1.2. Objectives 2
1.3. Methodology 2
1.4. Organization of thesis 3
Chapter 2: Literature Review 4
2.1. Classification of assembly line balancing problem 4
2.2. Existing optimization method 5
Chapter 3: Problem definition 7
3.1. Overview of shoe manufacturing process 7
3.2. Assembly line balancing problem in sewing lines 8
3.2.1. Problem characteristics 8
3.2.2. Decision complexity and frequency 11
3.3. Stage I - Tasks and equipments assignment to workstations 12
3.3.1. Objective function 13
3.3.2. Task renumbering 14
3.3.3. Generating sub-tasks 14
3.3.4. Mathematical program 15
3.4. Stage II - Workstations assignment to operators 17
Chapter 4 : Proposed method 19
4.1. Stage I - Task and equipment assignment to workstations 19
4.1.1. Heuristic method I (Stage I) 19
4.1.2. Branch and bound method (Stage I) 22
4.1.2.1. Bounding 22
4.1.2.2. Branching and Back-tracking procedure 25
4.2. Stage II - Task to workstation assignment 27
4.2.1. Heuristic method (Stage II) 27
4.2.2. Branch and bound method (Stage II) 29
4.2.2.1. Bounding 29
4.2.2.2. Branching and back-tracking method 31
4.3. Implementation on simplified numerical examples 33
4.3.1. Tasks to workstations assignment 33
4.3.2. Workstations assignment to operators 40
Chapter 5 : Numerical Experiment and Discussion 41
5.1. Tasks and equipments assignment to workstations 41
5.1.1. Full-factorial analysis 44
5.1.2. Method performance analysis 45
5.2. Workstations to operators assignment 46
Chapter 6 : Software Development and Implementation 48
Chapter 7 : Conclusion and Future Research 50
7.1. Conclusion 50
7.2. Future Research 50
References 52
Appendix 54
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