IDEAS home Printed from https://ideas.repec.org/a/eee/proeco/v270y2024ics0925527324000392.html
   My bibliography  Save this article

Order sequencing for a bucket brigade seru in a mass customization environment

Author

Listed:
  • Li, Dongni
  • Lyu, Yao
  • Zhang, Jinhui
  • Cui, Zihua
  • Yin, Yong

Abstract

In a mass customization environment, customer demands may change dramatically, which challenges conventional production systems. Seru production system (SPS) is a key to deal with changing varieties and fluctuated volumes. A bucket brigade seru is a divisional seru, in which partially cross-trained workers are organized as a bucket brigade. This paper studies an order sequencing problem for a bucket brigade seru with the objective of minimizing makespan. Dynamic behavior of a bucket brigade seru is modeled. Properties of the problem are presented that alternating the processing sequence of some products does not affect makespan. These properties provide factory managers with flexibility to adjust products processing sequence in case of changes in customer demands or lacks in materials. Six local search algorithms are developed using these properties, which combine three policies of selecting products in the operations of swap and insert. A bucket brigade local-search-based differential evolution (BLaDE) algorithm is proposed for the addressed problem, which may incorporate one of the six local search algorithms according to various scenarios. More than 14,000 instances are generated to evaluate the algorithms in terms of effectiveness, convergence, and stability. Experimental results demonstrate the superiority of BLaDE in volatile markets.

Suggested Citation

  • Li, Dongni & Lyu, Yao & Zhang, Jinhui & Cui, Zihua & Yin, Yong, 2024. "Order sequencing for a bucket brigade seru in a mass customization environment," International Journal of Production Economics, Elsevier, vol. 270(C).
    • Handle: RePEc:eee:proeco:v:270:y:2024:i:c:s0925527324000392
    DOI: 10.1016/j.ijpe.2024.109182
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0925527324000392
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ijpe.2024.109182?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    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. Aleda Roth & Jaya Singhal & Kalyan Singhal & Christopher S. Tang, 2016. "Knowledge Creation and Dissemination in Operations and Supply Chain Management," Production and Operations Management, Production and Operations Management Society, vol. 25(9), pages 1473-1488, September.
    2. Kuo-Ching Ying & Yi-Ju Tsai, 2017. "Minimising total cost for training and assigning multiskilled workers in production systems," International Journal of Production Research, Taylor & Francis Journals, vol. 55(10), pages 2978-2989, May.
    3. Henokh Yernias Fibrianto & Soondo Hong, 2019. "Dynamic order batching in bucket brigade order picking systems with consecutive batch windows and non-identical pickers," International Journal of Production Research, Taylor & Francis Journals, vol. 57(20), pages 6552-6568, October.
    4. Soondo Hong & Andrew L. Johnson & Brett A. Peters, 2016. "Order batching in a bucket brigade order picking system considering picker blocking," Flexible Services and Manufacturing Journal, Springer, vol. 28(3), pages 425-441, September.
    5. Yun Fong Lim, 2017. "Performance of Cellular Bucket Brigades with Hand-Off Times," Production and Operations Management, Production and Operations Management Society, vol. 26(10), pages 1915-1923, October.
    6. Nawaz, Muhammad & Enscore Jr, E Emory & Ham, Inyong, 1983. "A heuristic algorithm for the m-machine, n-job flow-shop sequencing problem," Omega, Elsevier, vol. 11(1), pages 91-95.
    7. Kathryn E. Stecke & Yong Yin & Ikou Kaku & Yasuhiko Murase, 2012. "Seru: The Organizational Extension of JIT for a Super-Talent Factory," International Journal of Strategic Decision Sciences (IJSDS), IGI Global, vol. 3(1), pages 106-119, January.
    8. Da Silveira, Giovani & Borenstein, Denis & Fogliatto, Flavio S., 2001. "Mass customization: Literature review and research directions," International Journal of Production Economics, Elsevier, vol. 72(1), pages 1-13, June.
    9. Yun Fong Lim & Yue Wu, 2014. "Cellular Bucket Brigades on U-Lines with Discrete Work Stations," Production and Operations Management, Production and Operations Management Society, vol. 23(7), pages 1113-1128, July.
    10. Liu, Ming & Yang, Xuenan & Chu, Feng & Zhang, Jiantong & Chu, Chengbin, 2020. "Energy-oriented bi-objective optimization for the tempered glass scheduling," Omega, Elsevier, vol. 90(C).
    11. Yun Fong Lim, 2011. "TECHNICAL NOTE---Cellular Bucket Brigades," Operations Research, INFORMS, vol. 59(6), pages 1539-1545, December.
    12. Yu, Yang & Tang, Jiafu & Sun, Wei & Yin, Yong & Kaku, Ikou, 2013. "Reducing worker(s) by converting assembly line into a pure cell system," International Journal of Production Economics, Elsevier, vol. 145(2), pages 799-806.
    13. John J. Bartholdi, III & Donald D. Eisenstein, 2005. "Using Bucket Brigades to Migrate from Craft Manufacturing to Assembly Lines," Manufacturing & Service Operations Management, INFORMS, vol. 7(2), pages 121-129, August.
    14. Zhe Zhang & Xiaoling Song & Huijun Huang & Yong Yin & Benjamin Lev, 2022. "Scheduling problem in seru production system considering DeJong’s learning effect and job splitting," Annals of Operations Research, Springer, vol. 312(2), pages 1119-1141, May.
    15. John J. Bartholdi & Donald D. Eisenstein, 1996. "A Production Line that Balances Itself," Operations Research, INFORMS, vol. 44(1), pages 21-34, February.
    16. John J. Bartholdi & Donald D. Eisenstein & Robert D. Foley, 2001. "Performance of Bucket Brigades When Work Is Stochastic," Operations Research, INFORMS, vol. 49(5), pages 710-719, October.
    Full references (including those not matched with items on IDEAS)

    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. Soondo Hong, 2018. "The effects of picker-oriented operational factors on hand-off delay in a bucket brigade order picking system," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 40(3), pages 781-808, July.
    2. Peng Wang & Kai Pan & Zhenzhen Yan & Yun Fong Lim, 2022. "Managing Stochastic Bucket Brigades on Discrete Work Stations," Production and Operations Management, Production and Operations Management Society, vol. 31(1), pages 358-373, January.
    3. Yun Fong Lim & Bingnan Lu & Rowan Wang & Wenjia Zhang, 2020. "Flexibly Serving A Finite Number of Heterogeneous Jobs in A Tandem System," Production and Operations Management, Production and Operations Management Society, vol. 29(6), pages 1431-1447, June.
    4. Ye Wang & Jiafu Tang, 2022. "Optimized skill configuration for the seru production system under an uncertain demand," Annals of Operations Research, Springer, vol. 316(1), pages 445-465, September.
    5. Zhang, Zhe & Song, Xiaoling & Gong, Xue & Yin, Yong & Lev, Benjamin & Zhou, Xiaoyang, 2024. "Coordinated seru scheduling and distribution operation problems with DeJong’s learning effects," European Journal of Operational Research, Elsevier, vol. 313(2), pages 452-464.
    6. Lili Wang & Min Li & Guanbin Kong & Haiwen Xu, 2024. "Joint decision-making for divisional seru scheduling and worker assignment considering process sequence constraints," Annals of Operations Research, Springer, vol. 338(2), pages 1157-1185, July.
    7. Zhe Zhang & Xiaoling Song & Huijun Huang & Yong Yin & Benjamin Lev, 2022. "Scheduling problem in seru production system considering DeJong’s learning effect and job splitting," Annals of Operations Research, Springer, vol. 312(2), pages 1119-1141, May.
    8. Zheng Wang & Jiuh‐Biing Sheu & Chung‐Piaw Teo & Guiqin Xue, 2022. "Robot Scheduling for Mobile‐Rack Warehouses: Human–Robot Coordinated Order Picking Systems," Production and Operations Management, Production and Operations Management Society, vol. 31(1), pages 98-116, January.
    9. Hong, Soondo & Johnson, Andrew L. & Peters, Brett A., 2015. "Quantifying picker blocking in a bucket brigade order picking system," International Journal of Production Economics, Elsevier, vol. 170(PC), pages 862-873.
    10. Zhang, Zhe & Gong, Xue & Song, Xiaoling & Yin, Yong & Lev, Benjamin & Chen, Jie, 2022. "A column generation-based exact solution method for seru scheduling problems," Omega, Elsevier, vol. 108(C).
    11. Zhang, Zhe & Song, Xiaoling & Huang, Huijung & Zhou, Xiaoyang & Yin, Yong, 2022. "Logic-based Benders decomposition method for the seru scheduling problem with sequence-dependent setup time and DeJong’s learning effect," European Journal of Operational Research, Elsevier, vol. 297(3), pages 866-877.
    12. Yun Fong Lim, 2011. "TECHNICAL NOTE---Cellular Bucket Brigades," Operations Research, INFORMS, vol. 59(6), pages 1539-1545, December.
    13. Sigrún Andradóttir & Hayriye Ayhan & Douglas G. Down, 2001. "Server Assignment Policies for Maximizing the Steady-State Throughput of Finite Queueing Systems," Management Science, INFORMS, vol. 47(10), pages 1421-1439, October.
    14. Li, Dongni & Jiang, Yuzhou & Zhang, Jinhui & Cui, Zihua & Yin, Yong, 2023. "An on-line seru scheduling algorithm with proactive waiting considering resource conflicts," European Journal of Operational Research, Elsevier, vol. 309(2), pages 506-515.
    15. Armbruster, Dieter & Gel, Esma S., 2006. "Bucket brigades revisited: Are they always effective?," European Journal of Operational Research, Elsevier, vol. 172(1), pages 213-229, July.
    16. Soondo Hong & Andrew L. Johnson & Brett A. Peters, 2016. "Order batching in a bucket brigade order picking system considering picker blocking," Flexible Services and Manufacturing Journal, Springer, vol. 28(3), pages 425-441, September.
    17. Yu, Yang & Tang, Jiafu & Gong, Jun & Yin, Yong & Kaku, Ikou, 2014. "Mathematical analysis and solutions for multi-objective line-cell conversion problem," European Journal of Operational Research, Elsevier, vol. 236(2), pages 774-786.
    18. Seyed M. Iravani & Mark P. Van Oyen & Katharine T. Sims, 2005. "Structural Flexibility: A New Perspective on the Design of Manufacturing and Service Operations," Management Science, INFORMS, vol. 51(2), pages 151-166, February.
    19. Sigrún Andradóttir & Hayriye Ayhan & Douglas G. Down, 2007. "Compensating for Failures with Flexible Servers," Operations Research, INFORMS, vol. 55(4), pages 753-768, August.
    20. Armbruster, Dieter & Gel, Esma S. & Murakami, Junko, 2007. "Bucket brigades with worker learning," European Journal of Operational Research, Elsevier, vol. 176(1), pages 264-274, January.

    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:270:y:2024:i:c:s0925527324000392. 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.