Assembly line balancing by using axiomatic design principles: An application from cooler manufacturing industry
The philosophy of production without waste is the fundamental belief behind lean manufacturing that should be adopted by enterprises. One of the waste elimination methods is assembly line balancing for lean manufacturing, i.e. Yamazumi. The assembly line balancing is to assign tasks to the workstations by minimizing the number of workstations to the required values. There should be no workstation with the excessively high or low workload, and all workstations must ideally work with balanced workloads. Accordingly, in this study, the axiomatic design method is applied for assembly line balancing in order to achieve maximum output with the installed capacity. In order to achieve this aim, all improvement opportunities are defined and utilized as an output of the study. Computational results indicate that the proposed method is effective to reduce operators’ idle time by 12%, imbalance workload between workstations by 38%, and the total number of workers by 12%. As a result of these improvements, the production volume is increased by 23%.
Ağpak, K , Gökçen, H , Saray, N , Özel, S . (2013). Stokastik Görev Zamanlı Tek Modelli U Tipi Montaj Hattı Dengeleme Problemleri İçin Bir Sezgisel. Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi , 17 (4). Retrieved from https://dergipark.org.tr/en/pub/gazimmfd/issue/6654/89311
Alcorta, L. (1999). Flexible automation and location of production in developing countries. The European Journal of Development Research, 11(1), 147-175. https://doi.org/10.1080/09578819908426731
Babic, B. (1999). Axiomatic design of flexible manufacturing systems. International Journal of Production Research, 37(5), 1159-1173. https://doi.org/10.1080/002075499191454
Black, J. T., Schroer, B. J. (1988). Decouplers in integrated cellular manufacturing systems. Journal of Engineering for Industry, 110(1), 77-85. https://doi.org/10.1115/1.3187846
Cakir, B. (2006). A simulation Annealing Algoirthm for Stochastic Process Time based Assembly Line Balancing, M.S. Thesis, Gazi University.
Celek, O. E., Yurdakul, M., Ic, T. (2019). Axiomatic Design of a Reconfigurable Assembly System for Aircraft Fuselages (No. 2019-01-1359). SAE Technical Paper. https://doi.org/10.4271/2019-01-1359
Cevikcan, E., Durmusoglu, M. B. (2011). Minimising utility work and utility worker transfers for a mixed-model assembly line. International Journal of Production Research, 49(24), 7293-7314. https://doi.org/10.1080/00207543.2010.537385
Chen, S. J. G., Chen, L. C., Lin, L. (2001). Knowledge-based support for simulation analysis of manufacturing cells. Computers in Industry, 44(1), 33-49. https://doi.org/10.1016/S0166-3615(00)00071-3
Chakraborty, K., Mondal, S., Mukherjee, K. (2017). Analysis of product design characteristics for remanufacturing using Fuzzy AHP and Axiomatic Design. Journal of Engineering Design, 28(5), 338-368. https://doi.org/10.1080/09544828.2017.1316014
Cochran, D. S., Eversheim, W., Kubin, G., Sesterhenn, M. L. (2000). The application of axiomatic design and lean management principles in the scope of production system segmentation. International Journal of Production Research,38(6), 1377-1396. https://doi.org/10.1080/002075400188906
Dolgui, A., Ihnatsenka, I. (2009). Branch and bound algorithm for a transfer line design problem: Stations with sequentially activated multi-spindle heads.European Journal of Operational Research, 197(3), 1119-1132. https://doi.org/10.1016/j.ejor.2008.03.028
Durmusoglu, M. B., Satoglu, S. I. (2011). Axiomatic design of hybrid manufacturing systems in erratic demand conditions. International Journal of Production Research, 49(17), 5231-5261. https://doi.org/10.1080/00207543.2010.510487
Ertay, T., Satoğlu, S. I. (2012). System parameter selection with information axiom for the new product introduction to the hybrid manufacturing systems under dual-resource constraint. International Journal of Production Research, 50(7), 1825-1839. https://doi.org/10.1080/00207543.2011.560205
Ghosh, S., Gagnon, R. J. (1989). A comprehensive literature review and analysis of the design, balancing and scheduling of assembly systems. The International Journal of Production Research, 27(4), 637-670. https://doi.org/10.1080/00207548908942574
Graves, S. C., Lamar, B. W. (1983). An integer programming procedure for assembly system design problems. Operations Research, 31(3), 522-545. https://doi.org/10.1287/opre.31.3.522
Gunasekera, J. S., Ali, A. F. (1995). A three-step approach to designing a metal-forming process. JOM, 47(6), 22-25. https://doi.org/10.1007/BF03221198
Guschinskaya, O., Dolgui, A., Guschinsky, N., Levin, G. (2008). A heuristic multi-start decomposition approach for optimal design of serial machining lines. European Journal of Operational Research, 189(3), 902-913. https://doi.org/10.1016/j.ejor.2006.03.072
Hager, T., Wafik, H., Faouzi, M. (2017). Manufacturing system design based on axiomatic design: Case of assembly line. Journal of Industrial Engineering and Management, 10(1), 111-139. https://doi.org/10.3926/jiem.728
Han, W. M., Zhao, J. L., Chen, Y. (2013). A Virtual Cellular Manufacturing System Design Model Based on Axiomatic Design Theory. In Applied Mechanics and Materials (Vol. 271, pp. 1478-1484). Trans Tech Publications. https://doi.org/10.4028/www.scientific.net/AMM.271-272.1478
Holzner, P., Rauch, E., Spena, P. R., Matt, D. T. (2015). Systematic Design of SME Manufacturing and Assembly Systems Based on Axiomatic Design.Procedia CIRP, 34, 81-86. https://doi.org/10.1016/j.procir.2015.07.010
Houshmand, M., Jamshidnezhad, B. (2002). Conceptual design of lean production systems through an axiomatic approach. In Proceedings of ICAD2002 Second International Conference on Axiomatic Design.
Houshmand, M., Jamshidnezhad, B. (2004). A lean manufacturing roadmap for an automotive body assembly line within axiomatic design framework. International Journal of Engineering Transactions, 17(1), 51-72.
Houshmand, M., Jamshidnezhad, B. (2006). An extended model of design process of lean production systems by means of process variables. Robotics and Computer-Integrated Manufacturing, 22(1), 1-16. https://doi.org/10.1016/j.rcim.2005.01.004
Khandekar, A. V., Chakraborty, S. (2016). Application of fuzzy axiomatic design principles for selection of non-traditional machining processes. The International Journal of Advanced Manufacturing Technology, 83(1-4), 529-543.
Kulak, O., Durmusoglu, M. B., Tufekci, S. (2005). A complete cellular manufacturing system design methodology based on axiomatic design principles. Computers & Industrial Engineering, 48(4), 765-787. https://doi.org/10.1016/j.cie.2004.12.006
Lipson, H., Suh, N. P. (2000). Towards a universal knowledge database for design automation. In Proceeding of ICAD2000, First International Conference on Axiomatic Design, pg (Vol. 250258, pp. 21-23).
Matt, D. T. (2008). Template based production system design. Journal of Manufacturing Technology Management, 19(7), 783-797. https://doi.org/10.1108/17410380810898741
Matt, D. T. (2012). Application of Axiomatic Design principles to control complexity dynamics in a mixed-model assembly system: a case analysis.International Journal of Production Research, 50(7), 1850-1861. https://doi.org/10.1080/00207543.2011.565086
Matt, D. T. (2013). Design of a scalable assembly system for product variety: a case study. Assembly Automation, 33(2), 117-126. https://doi.org/10.1108/01445151311306627
McMullen, P. R., Frazier, G. V. (1998). Using simulated annealing to solve a multiobjective assembly line balancing problem with parallel workstations. International Journal of Production Research, 36(10), 2717-2741. https://doi.org/10.1080/002075498192454
Nakao, M., Kobayashi, N., Hamada, K., Totsuka, T., Yamada, S. (2007). Decoupling executions in navigating manufacturing processes for shortening lead time and its implementation to an unmanned machine shop. CIRP Annals-Manufacturing Technology, 56(1), 171-174. https://doi.org/10.1016/j.cirp.2007.05.041
Nordlund, M., Tate, D., Suh, N. P. (1996). Growth of axiomatic design through industrial practice. In 3rd CIRP Workshop on Design and the Implementation of Intelligent Manufacturing Systems, Tokyo, Japan (Vol. 6, pp. 77-84).
Rauch, E., Spena, P. R., Matt, D. T. (2019). Axiomatic design guidelines for the design of flexible and agile manufacturing and assembly systems for SMEs. International Journal on Interactive Design and Manufacturing (IJIDeM), 13(1), 1-22. https://doi.org/10.1007/s12008-018-0460-1
Reynal, V. A., Cochran, D. S. (1996). Understanding lean manufacturing according to axiomatic design principles.
Suh, N. P. (1990). The principles of design (Vol. 990). New York: Oxford University Press.
Suh, N. P. (1995). Designing-in of quality through axiomatic design. IEEE Transactions on Reliability, 44(2), 256-264. https://doi.org/10.1109/24.387380
Suh, N. P. (1997). Design of systems. CIRP Annals-Manufacturing Technology,46(1), 75-80. https://doi.org/10.1016/S0007-8506(07)60779-3
Suh, N. P. (2001). Axiomatic Design: Advances and Applications (The Oxford Series on Advanced Manufacturing).
Vinodh, S., Aravindraj, S. (2012). Axiomatic modeling of lean manufacturing system. Journal of Engineering, Design and Technology, 10(2), 199-216. https://doi.org/10.1108/17260531211241185
Yilmaz, O. F., Cevikcan, E., Durmusoglu, M. B. (2016). Scheduling batches in multi hybrid cell manufacturing system considering worker resources: A case study from pipeline industry. Advances in Production Engineering & Management, 11(3). https://doi.org/10.14743/apem2016.3.220
Metrics powered by PLOS ALM
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License
Universitat Politècnica de València
e-ISSN: 2340-4876 ISSN: 2340-5317 https://doi.org/10.4995/ijpme