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Optimally locating in-house logistics areas to facilitate JIT-supply of mixed-model assembly lines

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  • Emde, Simon
  • Boysen, Nils

Abstract

In modern-day production systems, ever-rising product variety poses a great challenge for the internal logistics systems used to feed mixed-model assembly lines with the required parts. As an answer to this challenge many manufacturers especially from automobile industries have identified the supermarket-concept as a promising part feeding strategy to enable flexible small-lot deliveries at low cost. In this context, supermarkets are decentralized in-house logistics areas in the direct vicinity of the final assembly line, which serve as intermediary stores for parts. Small tow trains are loaded with material in a supermarket and deliver parts Just-in-Time to the stations lying on their fixed route. This paper discusses the general pros and cons of the supermarket-concept and treats the decision problem of determining the optimal number and placement of supermarkets on the shop floor. A mathematical model is proposed, an exact dynamic programming algorithm presented, and the validity of the proposed approach for practical purposes as well as the trade-off resulting from fixed installation and maintenance cost is investigated in a comprehensive computational study.

Suggested Citation

  • 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.
    • Handle: RePEc:eee:proeco:v:135:y:2012:i:1:p:393-402
    DOI: 10.1016/j.ijpe.2011.07.022
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    Cited by:

    1. Mohammed Hichame Benbitour & Evren Sahin, 2018. "The use of internal cross-docking in just-in-time plants," Post-Print hal-01793491, HAL.
    2. Masood Fathi & Morteza Ghobakhloo, 2020. "Enabling Mass Customization and Manufacturing Sustainability in Industry 4.0 Context: A Novel Heuristic Algorithm for in-Plant Material Supply Optimization," Sustainability, MDPI, vol. 12(16), pages 1-15, August.
    3. Diefenbach, Heiko & Emde, Simon & Glock, Christoph H., 2020. "Loading tow trains ergonomically for just-in-time part supply," European Journal of Operational Research, Elsevier, vol. 284(1), pages 325-344.
    4. 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.
    5. 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.
    6. Mohamed Amjath & Laoucine Kerbache & James MacGregor Smith, 2024. "A Closed Queueing Networks Approach for an Optimal Heterogeneous Fleet Size of an Inter-Facility Bulk Material Transfer System," Logistics, MDPI, vol. 8(1), pages 1-38, March.
    7. C. Briand & Y. He & S. U. Ngueveu, 2018. "Energy-efficient planning for supplying assembly lines with vehicles," EURO Journal on Transportation and Logistics, Springer;EURO - The Association of European Operational Research Societies, vol. 7(4), pages 387-414, December.
    8. Sternatz, Johannes, 2015. "The joint line balancing and material supply problem," International Journal of Production Economics, Elsevier, vol. 159(C), pages 304-318.
    9. Daria Battini & Nils Boysen & Simon Emde, 2013. "Just-in-Time supermarkets for part supply in the automobile industry," Metrika: International Journal for Theoretical and Applied Statistics, Springer, vol. 24(2), pages 209-217, July.
    10. 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.
    11. Masood Fathi & Amir Nourmohammadi & Morteza Ghobakhloo & Milad Yousefi, 2020. "Production Sustainability via Supermarket Location Optimization in Assembly Lines," Sustainability, MDPI, vol. 12(11), pages 1-15, June.
    12. Simon Emde & Lukas Polten, 2019. "Sequencing assembly lines to facilitate synchronized just-in-time part supply," Journal of Scheduling, Springer, vol. 22(6), pages 607-621, December.
    13. Emde, Simon & Gendreau, Michel, 2017. "Scheduling in-house transport vehicles to feed parts to automotive assembly lines," European Journal of Operational Research, Elsevier, vol. 260(1), pages 255-267.
    14. Stefan Fedtke & Nils Boysen & Patrick Schumacher, 2023. "In-line kitting for part feeding of assembly lines: workload balancing and storage assignment to reduce the workers’ walking effort," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 45(3), pages 717-758, September.

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