Identical parallel machine scheduling problem with sequence dependent setup time under machines eligibility restriction for heat exchanger assembly

Name: Thay, Seyha

keyword: Production scheduling

; Identical parallel machines

; Sequence dependent setup times

; Machine eligibility restriction

; Earliness and tardiness

Abstract: This research addresses a production scheduling problem in injection molding machines. It attempts to schedule product parts in injection molding machines, running as identical parallel machines with sequence-dependent setup times under machine eligibility restrictions. Based on a provided case study of an automotive supplier factory in Thailand, two stations are operating sequentially: injection molding machine line (upstream) and assembly line (downstream). However, these two stations are not well-coordinated since upstream could not produce the product parts on time required by downstream, so downstream must stop and wait. Besides, sometimes upstream over-produces some product parts, which are not immediately used according to production orders from downstream. Therefore, some product parts are stored longer in inventory, resulting in large inventory size. Hence, this research aims to formulate the production scheduling of the injection molding machine and produce the product parts to feed the heat exchanger assembly line. First of all, the improvement of production scheduling helps upstream produce the product parts on time to feed downstream, making both stations well-coordinated and operating smoothly. Secondly, this research provides the optimal production scheduling, which helps balance the inventory size between both stations to avoid having starvation in the downstream line and overproducing in the upstream line. Thirdly, this study provides insight into data arrangement due to the complex relationships among product-mold-machine. It formulates a process to arrange the given data according to the product specification and condition in the injection molding machine line. Last, this study has one further step to examine and find a better solution to whether the production line should be scheduled every day or every other day. The objective is to minimize the total earliness and tardiness of product parts to solve the inventory control problem and coordinate those two stations to operate smoothly and avoid bottlenecks. Mixed-integer programming is formulated to represent the condition and process of the plant's real injection molding machines. Different product parts and machines are arranged in different scenarios and tested using IBM ILOG CPLEX. The result shows that the product parts to be injected in the horizontal machines get the optimal production scheduling when scheduled to produce the product part every five-day, while product parts in vertical machines should be scheduled every thirty-day. The proposed method is used as the conceptual recommendation for all the production lines that synchronize between two stations in the production line by balancing the time to store the product parts in the inventory and eliminating the tardy job

Thammasat University. Thammasat University Library

Address: BANGKOK

Email: preserv@tu.ac.th

Name: Morrakot Raweewan

Role: advisor

Created: 2020

Modified: 2022-11-07

Issued: 2022-11-07

วิทยานิพนธ์/Thesis

application/pdf

DOI: 10.14457/TU.the.2020.85

eng

DegreeName: Master of Science

Level: Master's Degree

Descipline: Engineering and Technology

Grantor: Thammasat University

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