A mixed-model assembly line sequencing problem with parallel stations and walking workers: a case study in the automotive industry
基于菲亚特动力科技的真实案例，研究动态环境下带有走动工人的混合模型装配线排序问题，提出数学模型和超启发式算法，并用FlexSim仿真优化模型验证有效性，为管理者提供决策支持。
A newly emerging mass-individualisation concept has attracted increasing attention in recent years. However, this concept increases the complexity of manufacturing systems within organisations. In such systems, one of the main challenges is the sequencing problem, especially in dynamic environments where unpredictable events demand new constraints. In this context, the ability to use real-time data to make efficient, quick decisions has become one of the main priorities of managers. In this paper, based on a real-world case from Fiat Powertrain Technologies, we define a dynamic mixed-model assembly line sequencing problem with walking workers. In this context, each worker is assigned to a product for all assembly operations and moves from one station to another. A mathematical model is proposed to minimise production time. Since the problem is NP-hard, a hyper-heuristic is also developed to solve the problem. Moreover, a simulation-optimisation model is developed using FlexSim software to solve a real-world problem in a dynamic environment. Comparison of the results illustrates the effectiveness of using the simulation approach to dynamically solve such problems, especially in real-world cases. Finally, a thorough description of managerial insights is provided to indicate the applicability of the proposed approach.