IDEAS home Printed from https://ideas.repec.org/a/eee/proeco/v121y2009i1p233-254.html
   My bibliography  Save this article

Design of the optimal feeding policy in an assembly system

Author

Listed:
  • Battini, Daria
  • Faccio, Maurizio
  • Persona, Alessandro
  • Sgarbossa, Fabio

Abstract

This paper describes an innovative and integrated approach to component management optimization within a production/assembly system. In a mixed-models assembly process the handling of parts and components for each work station represents a substantial variable that can greatly affect job duration and efficiency. This paper is strictly related to Assembly to Order/Manufacturing to Order (ATO and MTO) systems, where lead time has to be very short and flexibility is at its maximum level. In Assembly to Order (ATO) or Make to Order (MTO) systems, the production is increasingly getting more customized in response to the demand, thanks to the progresses reached in both manufacturing and information technologies. It is becoming increasingly possible to assemble or make products specifically in response to the requests of either end customers or retailers. As a consequence of such customization, the design of the whole system must take into direct account several elements: parts warehouses location, feeding policies and feeding systems. In some cases the collection of parts and components required picking activities, in other the movement of entire units load. In several instances experts have analyzed the problems about material centralization/decentralization, storage policies and assembly feeding problem in different and independent ways, while the problem needs an integrated approach. While many researches regarding components allocation problems in ATO and MTO systems, did not consider feeding policies, material picking, packing activities and vehicles optimization, this paper cover focuses on filling such gap using an integrated framework that considers both aspects of the problem: the centralization/decentralization of components in order to minimize the total storage costs and the right feeding policies. Feeding problems in assembly lines are some of the most important aspects to consider during the analysis and design of an assembly system, to allow the maximization of efficiency and flexibility. To reach such goals, a multi-factorial analysis has been carried out during this experiment and will validate the introduced framework. An industrial application of the introduced framework is illustrated to explain its real significant production implication.

Suggested Citation

  • Battini, Daria & Faccio, Maurizio & Persona, Alessandro & Sgarbossa, Fabio, 2009. "Design of the optimal feeding policy in an assembly system," International Journal of Production Economics, Elsevier, vol. 121(1), pages 233-254, September.
    • Handle: RePEc:eee:proeco:v:121:y:2009:i:1:p:233-254
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0925-5273(09)00167-4
    Download Restriction: Full text for ScienceDirect subscribers only
    ---><---

    As the access to this document is restricted, you may want to search for a different version of it.

    References listed on IDEAS

    as
    1. Hillier, Mark S., 2002. "The costs and benefits of commonality in assemble-to-order systems with a (Q,r)-policy for component replenishment," European Journal of Operational Research, Elsevier, vol. 141(3), pages 570-586, September.
    2. E Kozan, 2000. "An integrated material handling system for a truck assembly plant," Journal of the Operational Research Society, Palgrave Macmillan;The OR Society, vol. 51(3), pages 263-271, March.
    3. Gary D. Eppen, 1979. "Note--Effects of Centralization on Expected Costs in a Multi-Location Newsboy Problem," Management Science, INFORMS, vol. 25(5), pages 498-501, May.
    4. Bellgran, Monica & Johansson, Christer, 1995. "A method for the design of flexible assembly systems," International Journal of Production Economics, Elsevier, vol. 41(1-3), pages 93-102, October.
    5. Mohebbi, E. & Choobineh, F., 2005. "The impact of component commonality in an assemble-to-order environment under supply and demand uncertainty," Omega, Elsevier, vol. 33(6), pages 472-482, December.
    6. Persona, Alessandro & Battini, Daria & Manzini, Riccardo & Pareschi, Arrigo, 2007. "Optimal safety stock levels of subassemblies and manufacturing components," International Journal of Production Economics, Elsevier, vol. 110(1-2), pages 147-159, October.
    7. Ramesh Bollapragada & Uday S. Rao & Jun Zhang, 2004. "Managing Inventory and Supply Performance in Assembly Systems with Random Supply Capacity and Demand," Management Science, INFORMS, vol. 50(12), pages 1729-1743, December.
    8. Yalçin Akçay & Susan H. Xu, 2004. "Joint Inventory Replenishment and Component Allocation Optimization in an Assemble-to-Order System," Management Science, INFORMS, vol. 50(1), pages 99-116, January.
    9. Nozick, Linda K. & Turnquist, Mark A., 2001. "Inventory, transportation, service quality and the location of distribution centers," European Journal of Operational Research, Elsevier, vol. 129(2), pages 362-371, March.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Boysen, Nils & Bock, Stefan, 2011. "Scheduling just-in-time part supply for mixed-model assembly lines," European Journal of Operational Research, Elsevier, vol. 211(1), pages 15-25, May.
    2. Emilio Moretti & Elena Tappia & Veronique Limère & Marco Melacini, 2021. "Exploring the application of machine learning to the assembly line feeding problem," Operations Management Research, Springer, vol. 14(3), pages 403-419, December.
    3. Boysen, Nils & Emde, Simon & Hoeck, Michael & Kauderer, Markus, 2015. "Part logistics in the automotive industry: Decision problems, literature review and research agenda," European Journal of Operational Research, Elsevier, vol. 242(1), pages 107-120.
    4. de Vries, Jan, 2013. "The influence of power and interest on designing inventory management systems," International Journal of Production Economics, Elsevier, vol. 143(2), pages 233-241.
    5. Mustapha Sali & Evren Sahin, 2016. "Line feeding optimization for Just in Time assembly lines: an application to the automotive industry," Post-Print hal-01265041, HAL.
    6. Maurizio Faccio & Mauro Gamberi & Alessandro Persona & Alberto Regattieri & Fabio Sgarbossa, 2013. "Design and simulation of assembly line feeding systems in the automotive sector using supermarket, kanbans and tow trains: a general framework," Metrika: International Journal for Theoretical and Applied Statistics, Springer, vol. 24(2), pages 187-208, July.
    7. Naliaka V.W. & G.S. Namusonge, 2015. "Role of Inventory Management on Competitive Advantage among Manufacturing Firms in Kenya: A Case Study of Unga Group Limited," International Journal of Academic Research in Business and Social Sciences, Human Resource Management Academic Research Society, International Journal of Academic Research in Business and Social Sciences, vol. 5(5), pages 87-104, May.
    8. Schmid, Nico André & Limère, Veronique & Raa, Birger, 2021. "Mixed model assembly line feeding with discrete location assignments and variable station space," Omega, Elsevier, vol. 102(C).
    9. Emilio Moretti & Elena Tappia & Martina Mauri & Marco Melacini, 2022. "A performance model for mobile robot-based part feeding systems to supermarkets," Flexible Services and Manufacturing Journal, Springer, vol. 34(3), pages 580-613, September.
    10. Sternatz, Johannes, 2015. "The joint line balancing and material supply problem," International Journal of Production Economics, Elsevier, vol. 159(C), pages 304-318.
    11. Emde, Simon & Boysen, Nils, 2012. "Optimally locating in-house logistics areas to facilitate JIT-supply of mixed-model assembly lines," International Journal of Production Economics, Elsevier, vol. 135(1), pages 393-402.
    12. Adenipekun, Ebenezer Olatunde & Limère, Veronique & Schmid, Nico André, 2022. "The impact of transportation optimisation on assembly line feeding," Omega, Elsevier, vol. 107(C).
    13. Sali, Mustapha & Sahin, Evren, 2016. "Line feeding optimization for Just in Time assembly lines: An application to the automotive industry," International Journal of Production Economics, Elsevier, vol. 174(C), pages 54-67.
    14. Francesco Lolli & Rita Gamberini & Claudio Giberti & Bianca Rimini & Federica Bondi, 2016. "A simulative approach for evaluating alternative feeding scenarios in a kanban system," International Journal of Production Research, Taylor & Francis Journals, vol. 54(14), pages 4228-4239, July.
    15. Hanson, Robin & Finnsgård, Christian, 2014. "Impact of unit load size on in-plant materials supply efficiency," International Journal of Production Economics, Elsevier, vol. 147(PA), pages 46-52.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Kai Huang, 2014. "Benchmarking non-first-come-first-served component allocation in an assemble-to-order system," Annals of Operations Research, Springer, vol. 223(1), pages 217-237, December.
    2. Çömez-Dolgan, Nagihan & Tanyeri, Başak, 2015. "Inventory performance with pooling: Evidence from mergers and acquisitions," International Journal of Production Economics, Elsevier, vol. 168(C), pages 331-339.
    3. Jing-Sheng Song & Yao Zhao, 2009. "The Value of Component Commonality in a Dynamic Inventory System with Lead Times," Manufacturing & Service Operations Management, INFORMS, vol. 11(3), pages 493-508, March.
    4. Yeu-Shiang Huang & Hau-Wen Lo & Jyh-Wen Ho, 2021. "Effects of component commonality and perishability on inventory control in assemble-to-order systems," Operational Research, Springer, vol. 21(1), pages 205-229, March.
    5. David A. Goldberg & Martin I. Reiman & Qiong Wang, 2021. "A Survey of Recent Progress in the Asymptotic Analysis of Inventory Systems," Production and Operations Management, Production and Operations Management Society, vol. 30(6), pages 1718-1750, June.
    6. Atan, Zümbül & Ahmadi, Taher & Stegehuis, Clara & Kok, Ton de & Adan, Ivo, 2017. "Assemble-to-order systems: A review," European Journal of Operational Research, Elsevier, vol. 261(3), pages 866-879.
    7. Hong, Yoo Suk & Huh, Woonghee Tim & Kang, Changmuk, 2017. "Sourcing assemble-to-order inventories under supplier risk uncertainty," Omega, Elsevier, vol. 66(PA), pages 1-14.
    8. Aydin Alptekinoglu & Arunava Banerjee & Anand Paul & Nikhil Jain, 2013. "Inventory Pooling to Deliver Differentiated Service," Manufacturing & Service Operations Management, INFORMS, vol. 15(1), pages 33-44, September.
    9. Ross, Anthony & Khajehnezhad, Milad & Otieno, Wilkistar & Aydas, Osman, 2017. "Integrated location-inventory modelling under forward and reverse product flows in the used merchandise retail sector: A multi-echelon formulation," European Journal of Operational Research, Elsevier, vol. 259(2), pages 664-676.
    10. Barros, Júlio & Cortez, Paulo & Carvalho, M. Sameiro, 2021. "A systematic literature review about dimensioning safety stock under uncertainties and risks in the procurement process," Operations Research Perspectives, Elsevier, vol. 8(C).
    11. Liu, Kaijun & Zhou, Yonghong & Zhang, Zigang, 2010. "Capacitated location model with online demand pooling in a multi-channel supply chain," European Journal of Operational Research, Elsevier, vol. 207(1), pages 218-231, November.
    12. Jan A. Van Mieghem & Nils Rudi, 2002. "Newsvendor Networks: Inventory Management and Capacity Investment with Discretionary Activities," Manufacturing & Service Operations Management, INFORMS, vol. 4(4), pages 313-335, August.
    13. Ho-Yin Mak & Zuo-Jun Max Shen, 2014. "Pooling and Dependence of Demand and Yield in Multiple-Location Inventory Systems," Manufacturing & Service Operations Management, INFORMS, vol. 16(2), pages 263-269, May.
    14. Barcos, Lucía & Barroso, Alicia & Surroca, Jordi & Tribó, Josep A., 2013. "Corporate social responsibility and inventory policy," International Journal of Production Economics, Elsevier, vol. 143(2), pages 580-588.
    15. Lingxiu Dong & Nils Rudi, 2004. "Who Benefits from Transshipment? Exogenous vs. Endogenous Wholesale Prices," Management Science, INFORMS, vol. 50(5), pages 645-657, May.
    16. Lee, Loo Hay & Chew, Ek Peng & Manikam, Puvaneswari, 2006. "A general framework on the simulation-based optimization under fixed computing budget," European Journal of Operational Research, Elsevier, vol. 174(3), pages 1828-1841, November.
    17. Francesco Cappa & Fausto Del Sette & Darren Hayes & Federica Rosso, 2016. "How to Deliver Open Sustainable Innovation: An Integrated Approach for a Sustainable Marketable Product," Sustainability, MDPI, vol. 8(12), pages 1-14, December.
    18. Straubert, Christian, 2024. "A continuous approximation location-inventory model with exact inventory costs and nonlinear delivery lead time penalties," International Journal of Production Economics, Elsevier, vol. 268(C).
    19. Jiri Chod & Nils Rudi, 2005. "Resource Flexibility with Responsive Pricing," Operations Research, INFORMS, vol. 53(3), pages 532-548, June.
    20. Rafiei, Rezvan & Huang, Kai & Verma, Manish, 2022. "Cash versus in-kind transfer programs in humanitarian operations: An optimization program and a case study," Socio-Economic Planning Sciences, Elsevier, vol. 82(PA).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:proeco:v:121:y:2009:i:1:p:233-254. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/locate/ijpe .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.