Tri-objective optimisation of mixed model reconfigurable assembly system for modular products

ABSTRACT

The recent challenges for assembly-based manufacturing are primarily governed by dynamic market with mass customisation requirements. In this context, modular products are gaining attentions after success in automobile, electronics and many other sectors. Another contemporary research on reconfigurable assembly system (RAS) is a manifestation of reconfigurable manufacturing system (RMS) philosophy in mixed-model assembly operations to handle flexibility issues in functionality and capacity. In this paper, an integration model for these two state-of-the-art design and assembly philosophies are presented. A tri-objective formulation and module selection plans are developed for modular products in an RAS environment. Non-dominated Pareto optimal solutions considering assembly cycle time, balance delay and smoothness indices as three objectives are found to select optimal product modules during assembly process. The assumptions and features of this model are complying with a typical manufacturer from auto or electronics industries having some parts outsourced to original equipment manufacturers (OEMs). An industrial case study dealing with assembly of automobile engines is included as a base model to illustrate the application and scope of the research.

KEYWORDS:

• Modular products
• reconfigurable assembly systems
• Pareto optimality
• aggregate weight
• balance delay
• smoothness index

Acknowledgements

The authors wish to thank the two anonymous referees for their valued review and suggestions to improve the content and presentation of the paper. The authors are also thankful to the management and technical staffs of Tata Cummins Pvt Ltd. for their help and cooperation in carrying out this research work.

Disclosure statement

No potential conflict of interest was reported by the authors.