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Backup strategy for robots' failures in an automotive assembly system

Author

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  • Kahan, Tomer
  • Bukchin, Yossi
  • Menassa, Roland
  • Ben-Gal, Irad

Abstract

Automotive assembly lines are often characterized by robots' failures that may result in stoppages of the lines and manual backup of tasks. The phenomena tend to impair throughput rate and products' quality. This paper presents a backup strategy in which working robots perform tasks of failed robots. The proposed Mixed-Integer Linear-Programming based approach minimizes the throughput loss by utilizing the robots' redundancy in the system. Two algorithms are developed to comply with stochastic conditions of a real-world environment. The performance of these algorithms is compared with several heuristics, and the downstream-backup based algorithm is found superior to all other methods.

Suggested Citation

  • Kahan, Tomer & Bukchin, Yossi & Menassa, Roland & Ben-Gal, Irad, 2009. "Backup strategy for robots' failures in an automotive assembly system," International Journal of Production Economics, Elsevier, vol. 120(2), pages 315-326, August.
    • Handle: RePEc:eee:proeco:v:120:y:2009:i:2:p:315-326
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    References listed on IDEAS

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    1. Becker, Christian & Scholl, Armin, 2006. "A survey on problems and methods in generalized assembly line balancing," European Journal of Operational Research, Elsevier, vol. 168(3), pages 694-715, February.
    2. Amen, Matthias, 2000. "Heuristic methods for cost-oriented assembly line balancing: A survey," International Journal of Production Economics, Elsevier, vol. 68(1), pages 1-14, October.
    3. Scholl, Armin & Becker, Christian, 2006. "State-of-the-art exact and heuristic solution procedures for simple assembly line balancing," European Journal of Operational Research, Elsevier, vol. 168(3), pages 666-693, February.
    4. Boysen, Nils & Fliedner, Malte & Scholl, Armin, 2008. "Assembly line balancing: Which model to use when," International Journal of Production Economics, Elsevier, vol. 111(2), pages 509-528, February.
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    Cited by:

    1. Battaïa, Olga & Dolgui, Alexandre, 2013. "A taxonomy of line balancing problems and their solutionapproaches," International Journal of Production Economics, Elsevier, vol. 142(2), pages 259-277.
    2. Lai, Tsung-Chyan & Sotskov, Yuri N. & Dolgui, Alexandre, 2019. "The stability radius of an optimal line balance with maximum efficiency for a simple assembly line," European Journal of Operational Research, Elsevier, vol. 274(2), pages 466-481.
    3. Christoph Müller & Martin Grunewald & Thomas S. Spengler, 2017. "Redundant configuration of automated flow lines based on “Industry 4.0”-technologies," Journal of Business Economics, Springer, vol. 87(7), pages 877-898, October.
    4. Johanna Hautala, 2021. "Can robots possess knowledge? Rethinking the DIK(W) pyramid through the lens of employees of an automotive factory," Palgrave Communications, Palgrave Macmillan, vol. 8(1), pages 1-10, December.
    5. Lai, Tsung-Chyan & Sotskov, Yuri N. & Dolgui, Alexandre & Zatsiupa, Aksana, 2016. "Stability radii of optimal assembly line balances with a fixed workstation set," International Journal of Production Economics, Elsevier, vol. 182(C), pages 356-371.
    6. Kiesmüller, G.P. & Sachs, F.E., 2020. "Spare parts or buffer? How to design a transfer line with unreliable machines," European Journal of Operational Research, Elsevier, vol. 284(1), pages 121-134.

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