Enhanced mixed integer programming model for a transfer line design problem

Modular machining lines with multi-spindle workstations are considered. A multi-spindle head executes a set of operations. The problem of optimal design or reconfiguration of such lines is considered here. The set of all available spindle heads, operations executed by each spindle head, spindle head times and costs are assumed to be known. There are operations which can be executed by one of several candidate spindle heads, i.e., in different configuration with other operations. The problem consists in the choice of spindle heads from the given set and their assignment to workstations. The goal is to minimize the line cost while satisfying the precedence, inclusion and exclusion constraints. This problem is an extension of well known assembly line balancing and equipment selection problem. In our previous work, we proposed a MIP model which was significantly limited as to the size of the problems treated. In this paper, quite a few original approaches are suggested to improve the previous MIP model. The numerical tests reported show that the calculation time is drastically decreased, thereby expanding the model to larger and more realistic industrial problems.

► We study a problem of optimal design or reconfiguration of production/assembly lines.
► Original techniques are suggested to improve a mixed integer programming model.
► Tests show that the average calculation time is drastically decreased (up to 1745 times).
► This opens the possibility to consider larger industrial sized problems.
► The techniques proposed should be useful in other line design and balancing models.