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Pereira, J. (2018). The robust (minmax regret) assembly line worker assignment and balancing problem. Comput. Oper. Res., 93, 27–40.
Abstract: Line balancing aims to assign the assembly tasks to the stations that compose the assembly line. A recent body of literature has been devoted to heterogeneity in the assembly process introduced by different workers. In such an environment, task times depend on the worker performing the operation and the problem aims at assigning tasks and workers to stations in order to maximize the throughput of the line. In this work, we consider an interval data version of the assembly line worker assignment and balancing problem (ALWABP) in which it is assumed that lower and upper bounds for the task times are known, and the objective is to find an assignment of tasks and workers to the workstations such that the absolute maximum regret among all of the possible scenarios is minimized. The relationship with other interval data minmax regret (IDMR) problems is investigated, the inapplicability of previous approximation methods is studied, regret evaluation is considered, and exact and heuristic solution methods are proposed and analyzed. The results of the proposed methods are compared in a computational experiment, showing the applicability of the method and the theoretical results to solve the problem under study. Additionally, these results are not only applicable to the problem in hand, but also to a more general class of problems. (C) 2018 Elsevier Ltd. All rights reserved.
Keywords: Production; Line balancing; Robust optimization; Minmax regret
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Pereira, J. (2018). Modelling and solving a cost-oriented resource-constrained multi-model assembly line balancing problem. Int. J. Prod. Res., 56(11), 3994–4016.
Abstract: A line balancing problem considers the assignment of operations to workstations in an assembly line. While assembly lines are usually associated to mass production of standardised goods, their advantages have led to their widespread use whenever a product-oriented production system is applicable and the benefits of the labour division and specialisation are significant, even when some of its characteristics may deviate from classical assembly lines. In this work, we study a line balancing problem found in the textile industry in which the line must be balanced for multiple types of goods taking into account resource requirements. In order to solve the problem, a hybrid method that combines classical methods for line balancing with an Estimation of Distribution Algorithm is proposed. Computational experiments show that the new procedure improves upon the state of the art when compared using a benchmark set derived from the literature, as well as when compared using data from the manufacturer that originated this research work.
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Pereira, J., & Ritt, M. (2023). Exact and heuristic methods for a workload allocation problem with chain precedence constraints. Eur. J. Oper. Res., 309(1), 387–398.
Abstract: Industrial manufacturing is often organized in assembly lines where a product is assembled on a se-quence of stations, each of which executes some of the assembly tasks. A line is balanced if the maximum total execution time of any station is minimal. Commonly, the task execution order is constrained by precedences, and task execution times are independent of the station performing the task. Here, we con -sider a recent variation, called the “(Calzedonia) Workload Allocation Problem” (WAP), where the prece-dences form a chain, and the execution time of a task depends on the worker executing it. This problem was recently proposed by Battarra et al. (2020) and it is a special case of the Assembly Line Worker As-signment and Balancing Problem Miralles et al. (2007) where precedence relations are arbitrary. In this paper we consider the computational complexity of the problem and prove its NP-hardness. To solve the problem, we provide different lower bounds and exact and heuristic procedures. The performance of the proposed methods is tested on previously proposed instances and on new, larger instances with the same characteristics. The results show that the proposed methods can solve instances with up to about 40 0 0 tasks and 29 workers, doubling the size of the instances that previously could be solved to optimality.
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Pereira, J., & Alvarez-Miranda, E. (2018). An exact approach for the robust assembly line balancing problem. Omega-Int. J. Manage. Sci., 78, 85–98.
Abstract: This work studies an assembly line balancing problem with uncertainty on the task times. In order to deal with the uncertainty, a robust formulation to handle changes in the operation times is put forward. In order to solve the problem, several lower bounds, dominance rules and an enumeration procedure are proposed. These methods are tested in a computational experiment using different instances derived from the literature and then compared to similar previous approaches. The results of the experiment show that the method is able to solve larger instances in shorter running times. Furthermore, the cost of protecting a solution against uncertainty is also investigated. The results highlight that protecting an assembly line against moderate levels of uncertainty can be achieved at the expense of small quantities of additional resources (stations). (C) 2017 Elsevier Ltd. All rights reserved.
Keywords: Line balancing; Robust optimization; Lower bounds; Branch-and-bound
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Pereira, J., & Ritt, M. (2022). A note on “Algorithms for the Calzedonia workload allocation problem”. J. Oper. Res. Soc., 73(6), 1420–1422.
Abstract: Battarra et al. recently proposed a novel assembly line balancing problem with applications to the apparel industry, where the tasks are performed in a fixed order. To solve the problem, one has to assign workers and tasks to the workstations with the objective of maximising the throughput of the assembly line. In this paper, we provide dynamic programming formulations for the general problem and some special cases. We then use these formulations to develop an exact solution approach that optimally solves the instances in Battarra et al. within seconds.
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Pereira, J., Ritt, M., & Vasquez, O. C. (2018). A memetic algorithm for the cost-oriented robotic assembly line balancing problem. Comput. Oper. Res., 99, 249–261.
Abstract: In order to minimize costs, manufacturing companies have been relying on assembly lines for the mass production of commodity goods. Among other issues, the successful operation of an assembly line requires balancing work among the stations of the line in order to maximize its efficiency, a problem known in the literature as the assembly line balancing problem, ALBP. In this work, we consider an ALBP in which task assignment and equipment decisions are jointly considered, a problem that has been denoted as the robotic ALBP. Moreover, we focus on the case in which equipment has different costs, leading to a cost-oriented formulation. In order to solve the problem, which we denote as the cost-oriented robotic assembly line balancing problem, cRALBP, a hybrid metaheuristic is proposed. The metaheuristic embeds results obtained for two special cases of the problem within a genetic algorithm in order to obtain a memetic algorithm, applicable to the general problem. An extensive computational experiment shows the advantages of the hybrid approach and how each of the components of the algorithm contributes to the overall ability of the method to obtain good solutions. (C) 2018 Elsevier Ltd. All rights reserved.
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Pereira, J., & Vasquez, O. C. (2017). The single machine weighted mean squared deviation problem. Eur. J. Oper. Res., 261(2), 515–529.
Abstract: This paper studies a single machine problem related to the just-In-Time (JIT) production objective in which the goal is to minimize the sum of weighted mean squared deviation of the completion times with respect to a common due date. In order to solve the problem, several structural and dominance properties of the optimal solution are investigated. These properties are then integrated within a branch and-cut approach to solve a time-indexed formulation of the problem. The results of a computational experiment with the proposed algorithm show that the method is able to optimally solve instances with up to 300 jobs within reduced running times, improving other integer programming approaches. (C) 2017 Elsevier B.V. All rights reserved.
Keywords: Scheduling; Single machine; JIT; Branch-and-cut; Dominance properties
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Pereira, J., & Vila, M. (2016). A new model for supply chain network design with integrated assembly line balancing decisions. Int. J. Prod. Res., 54(9), 2653–2669.
Abstract: Supply chain network design aims at the integration of the different actors of a supply chain within a single framework in order to optimise the total profit of the system. In this paper, we consider the integration of line balancing issues within the tactical decisions of the supply chain, and we offer a novel model and a solution approach for the problem. The new approach decomposes the problem into multiple line balancing problems and a mixed integer linear model, which is easier to solve than the previously available non-linear mixed integer formulation. The results show that the new method is able to solve previously studied models within a fraction of the reported running times, and also allows us to solve larger instances than those reported in earlier works. Finally, we also provide some analysis on the influence of the cost structure, the demand and the structure of the assembly process on the final configuration of the assemblies and the distribution network.
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Ritt, M., & Pereira, J. (2020). Heuristic and exact algorithms for minimum-weight non-spanning arborescences. Eur. J. Oper. Res., 287(1), 61–75.
Abstract: We address the problem of finding an arborescence of minimum total edge weight rooted at a given vertex in a directed, edge-weighted graph. If the arborescence must span all vertices the problem is solvable in polynomial time, but the non-spanning version is NP-hard. We propose reduction rules which determine vertices that are required or can be excluded from optimal solutions, a modification of Edmonds algorithm to construct arborescences that span a given set of selected vertices, and embed this procedure into an iterated local search for good vertex selections. Moreover, we propose a cutset-based integer linear programming formulation, provide different linear relaxations to reduce the number of variables in the model and solve the reduced model using a branch-and-cut approach. We give extensive computational results showing that both the heuristic and the exact methods are effective and obtain better solutions on instances from the literature than existing approaches, often in much less time. (C) 2020 Elsevier B.V. All rights reserved.
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Sandoval, G., Alvarez-Miranda, E., Pereira, J., Rios-Mercado, R. Z., & Diaz, J. A. (2022). A novel districting design approach for on-time last-mile delivery: An application on an express postal company. Omega-Int. J. Manage. Sci., 113, 102687.
Abstract: Last-mile logistics corresponds to the last leg of the supply chain, i.e., the delivery of goods to final cus-tomers, and they comprise the core activities of postal and courier companies. Because of their role in the supply chain, last-mile operations are critical for the perception of customers regarding the perfor-mance of the whole logistic process. In this sense, the sustained growth of e-commerce, which has been abruptly catalyzed by the irruption of the COVID-19 pandemic, has hanged the habits of customers and overtaxed the operational side of delivery companies, hindering their viability and forcing their adap-tation to the novel conditions. Many of these habits will remain after we overcome the sanitary crisis, which will permanently reshape the structure and emphasis of postal supply chains, demanding compa-nies to implement organizational and operational changes to adapt to these new challenges. In this work we address a last-mile logistic design problem faced by a courier and delivery company in Chile, although the same problem is likely to arise in the last-mile delivery operation of other postal companies, in particular in the operation of express delivery services. The operational structure of the company is based on the division of an urban area into smaller territories (districts) and the outsourcing of the delivery operation of each territory to a last-mile contractor. Because of the increasing volume of postal traffic and a decreasing performance of the service, in particular for the case of express deliveries, the company is forced to redesign its current territorial arrangement. Such redesign results in a novel optimization problem that resembles a classical districting problem with the additional quality of service requirements. This novel problem is first formulated as a mathematical programming model and then a specially tailored heuristic is designed for solving it. The proposed approach is tested on instances from the real-life case study, and the obtained results show significant improvements in terms of the percent-age of on-time deliveries achieved by the proposed solution when compared to the current districting design of the company. By performing a sensitivity analysis considering different levels of demand, we show that the proposed approach is effective in providing districting designs capable of enduring signifi-cant increases in the demand for express postal services.
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Yuraszeck, F., Mejia, G., Pereira, J., & Vila, M. (2022). A Novel Constraint Programming Decomposition Approach for the Total Flow Time Fixed Group Shop Scheduling Problem. Mathematics, 10(3), 329.
Abstract: This work addresses a particular case of the group shop scheduling problem (GSSP) which will be denoted as the fixed group shop scheduling problem (FGSSP). In a FGSSP, job operations are divided into stages and each stage has a set of machines associated to it which are not shared with the other stages. All jobs go through all the stages in a specific order, where the operations of the job at each stage need to be finished before the job advances to the following stage, but operations within a stage can be performed in any order. This setting is common in companies such as leaf spring manufacturers and other automotive companies. To solve the problem, we propose a novel heuristic procedure that combines a decomposition approach with a constraint programming (CP) solver and a restart mechanism both to avoid local optima and to diversify the search. The performance of our approach was tested on instances derived from other scheduling problems that the FGSSP subsumes, considering both the cases with and without anticipatory sequence-dependent setup times. The results of the proposed algorithm are compared with off-the-shelf CP and mixed integer linear programming (MILP) methods as well as with the lower bounds derived from the study of the problem. The experiments show that the proposed heuristic algorithm outperforms the other methods, specially on large-size instances with improvements of over 10% on average.
Keywords: scheduling; fixed group shop; group shop; constraint programming
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