IDEAS home Printed from https://ideas.repec.org/a/gam/jsusta/v12y2020i16p6669-d400469.html
   My bibliography  Save this article

Enabling Mass Customization and Manufacturing Sustainability in Industry 4.0 Context: A Novel Heuristic Algorithm for in-Plant Material Supply Optimization

Author

Listed:
  • Masood Fathi

    (Department of Production and Automation Engineering, University of Skövde, SE-541 28 Skövde, Sweden)

  • Morteza Ghobakhloo

    (Department of Industrial Engineering, Minab Higher Education Center, University of Hormozgan, Bandar Abbas 79177, Iran)

Abstract

The fourth industrial revolution and the digital transformation of consumer markets require contemporary manufacturers to rethink and reshape their business models to deal with the ever-changing customer demands and market turbulence. Manufacturers nowadays are inclined toward product differentiation strategies and more customer-focused approaches to stay competitive in the Industry 4.0 environment, and mass customization and product diversification are among the most commonly implemented business models. Under such circumstances, an economical material supply to assembly lines has become a significant concern for manufacturers. Consequently, the present study deals with optimizing the material supply to mixed-model assembly lines that contribute to the overall production cost efficiency, mainly via the reduction of both the material transportation and material holding costs across production lines, while satisfying certain constraints. Given the complexity of the problem, a novel two-stage heuristic algorithm is developed in this study to enable a cost-efficient delivery. To assess the efficiency and effectiveness of the proposed heuristic algorithm, a set of test problems are solved and compared against the best solution found by a commercial solver. The results of the comparison reveal that the suggested heuristic provides reasonable solutions, thus offering immense opportunities for production cost efficiency and manufacturing sustainability under the mass customization philosophy.

Suggested Citation

  • 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.
    • Handle: RePEc:gam:jsusta:v:12:y:2020:i:16:p:6669-:d:400469
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/2071-1050/12/16/6669/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/2071-1050/12/16/6669/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Branislav Micieta & Vladimira Binasova & Radovan Lieskovsky & Martin Krajcovic & Luboslav Dulina, 2019. "Product Segmentation and Sustainability in Customized Assembly with Respect to the Basic Elements of Industry 4.0," Sustainability, MDPI, vol. 11(21), pages 1-20, October.
    2. Mosadegh, H. & Fatemi Ghomi, S.M.T. & Süer, G.A., 2020. "Stochastic mixed-model assembly line sequencing problem: Mathematical modeling and Q-learning based simulated annealing hyper-heuristics," European Journal of Operational Research, Elsevier, vol. 282(2), pages 530-544.
    3. Emde, Simon & Schneider, Michael, 2018. "Just-In-Time Vehicle Routing for In-House Part Feeding to Assembly Lines," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 96055, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    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. Emde, Simon & Fliedner, Malte & Boysen, Nils, 2012. "Optimally loading tow trains for just-in-time supply of mixed-model assembly lines," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 79434, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    6. Minfang Huang & Qiong Guo & Jing Liu & Xiaoxu Huang, 2018. "Mixed Model Assembly Line Scheduling Approach to Order Picking Problem in Online Supermarkets," Sustainability, MDPI, vol. 10(11), pages 1-16, October.
    7. Boysen, Nils & Emde, Simon & Hoeck, Michael & Kauderer, Markus, 2015. "Part logistics in the automotive industry: Decision problems, literature review and research agenda," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 79443, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    8. 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.
    9. 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.
    10. Boysen, Nils & Fliedner, Malte & Scholl, Armin, 2009. "Sequencing mixed-model assembly lines: Survey, classification and model critique," European Journal of Operational Research, Elsevier, vol. 192(2), pages 349-373, January.
    11. Masood Fathi & Victoria Rodríguez & Dalila B.M.M. Fontes & Maria Jesus Alvarez, 2016. "A modified particle swarm optimisation algorithm to solve the part feeding problem at assembly lines," International Journal of Production Research, Taylor & Francis Journals, vol. 54(3), pages 878-893, February.
    12. Emde, Simon & Boysen, Nils, 2012. "Optimally locating in-house logistics areas to facilitate JIT-supply of mixed-model assembly lines," Publications of Darmstadt Technical University, Institute for Business Studies (BWL) 79445, Darmstadt Technical University, Department of Business Administration, Economics and Law, Institute for Business Studies (BWL).
    13. Emde, Simon & Boysen, Nils, 2012. "Optimally routing and scheduling tow trains for JIT-supply of mixed-model assembly lines," European Journal of Operational Research, Elsevier, vol. 217(2), pages 287-299.
    14. 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.
    15. Simon Emde & Michael Schneider, 2018. "Just-In-Time Vehicle Routing for In-House Part Feeding to Assembly Lines," Transportation Science, INFORMS, vol. 52(3), pages 657-672, June.
    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. Yuli Liang & Snigdha Rangineni & Chuanlan Liu, 2022. "Fashion or Function: Examining Consumers' Perceived Values of Mass-Customized Menswear via a Content Mining Approach," International Journal of Business Analytics (IJBAN), IGI Global, vol. 9(6), pages 1-18, October.
    2. Basile, Vincenzo & Tregua, Marco & Giacalone, Massimiliano, 2024. "A three-level view of readiness models: Statistical and managerial insights on industry 4.0," Technology in Society, Elsevier, vol. 77(C).
    3. Caiming Zhang & Yong Chen & Hong Chen & Dazhi Chong, 2024. "Industry 4.0 and its Implementation: a Review," Information Systems Frontiers, Springer, vol. 26(5), pages 1773-1783, October.
    4. Fawaz M. Abdullah & Abdulrahman M. Al-Ahmari & Saqib Anwar, 2023. "Analyzing Interdependencies among Influencing Factors in Smart Manufacturing," Sustainability, MDPI, vol. 15(4), pages 1-19, February.
    5. Sam Solaimani & Alireza Parandian & Nabi Nabiollahi, 2021. "A Holistic View on Sustainability in Additive and Subtractive Manufacturing: A Comparative Empirical Study of Eyewear Production Systems," Sustainability, MDPI, vol. 13(19), pages 1-17, September.

    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. 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.
    2. Diefenbach, Heiko & Emde, Simon & Glock, Christoph H., 2023. "Multi-depot electric vehicle scheduling in in-plant production logistics considering non-linear charging models," European Journal of Operational Research, Elsevier, vol. 306(2), pages 828-848.
    3. 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.
    4. 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.
    5. 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.
    6. 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.
    7. Simon Emde & Michael Schneider, 2018. "Just-In-Time Vehicle Routing for In-House Part Feeding to Assembly Lines," Transportation Science, INFORMS, vol. 52(3), pages 657-672, June.
    8. 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.
    9. Baals, Julian & Emde, Simon & Turkensteen, Marcel, 2023. "Minimizing earliness-tardiness costs in supplier networks—A just-in-time truck routing problem," European Journal of Operational Research, Elsevier, vol. 306(2), pages 707-741.
    10. 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.
    11. Simon Emde, 2017. "Scheduling the replenishment of just-in-time supermarkets in assembly plants," OR Spectrum: Quantitative Approaches in Management, Springer;Gesellschaft für Operations Research e.V., vol. 39(1), pages 321-345, January.
    12. Sternatz, Johannes, 2015. "The joint line balancing and material supply problem," International Journal of Production Economics, Elsevier, vol. 159(C), pages 304-318.
    13. 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.
    14. Bock, Stefan, 2020. "Optimally solving a versatile Traveling Salesman Problem on tree networks with soft due dates and multiple congestion scenarios," European Journal of Operational Research, Elsevier, vol. 283(3), pages 863-882.
    15. Stefan Bock, 2016. "Finding optimal tour schedules on transportation paths under extended time window constraints," Journal of Scheduling, Springer, vol. 19(5), pages 527-546, October.
    16. Masood Fathi & Victoria Rodríguez & Dalila B.M.M. Fontes & Maria Jesus Alvarez, 2016. "A modified particle swarm optimisation algorithm to solve the part feeding problem at assembly lines," International Journal of Production Research, Taylor & Francis Journals, vol. 54(3), pages 878-893, February.
    17. 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.
    18. Boysen, Nils & Emde, Simon, 2014. "Scheduling the part supply of mixed-model assembly lines in line-integrated supermarkets," European Journal of Operational Research, Elsevier, vol. 239(3), pages 820-829.
    19. 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.
    20. Boysen, Nils & Schulze, Philipp & Scholl, Armin, 2022. "Assembly line balancing: What happened in the last fifteen years?," European Journal of Operational Research, Elsevier, vol. 301(3), pages 797-814.

    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:gam:jsusta:v:12:y:2020:i:16:p:6669-:d:400469. 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: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    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.