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Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration

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Abstract

Green manufacturing is a growing trend, and an effective layout design method for production lines can reduce resource wastage in processing. This study focuses on existing problems such as low equipment utilization, long standby time, and low logistics efficiency in a mixed-flow parallel production line. To reduce the energy consumption, a novel method considering an independent buffer configuration and idle energy consumption analysis is proposed for this production line’s layout design. A logistics intensity model and a machine tool availability model are established to investigate the influences of independent buffer area configuration on the logistics intensity and machine tool availability. To solve the coupling problem between machine tools in such production lines, a decoupling strategy for the relationship between machine tool processing rates is explored. An energy consumption model for the machine tools, based on an optimized configuration of independent buffers, is proposed. This model can effectively reduce the idle energy consumption of the machine tools while designing the workshop layout. Subsequently, considering the problems encountered in workshop production, a comprehensive optimization model for the mixed-flow production line is developed. To verify the effectiveness of the mathematical model, it is applied to an aviation cabin production line. The results indicate that it can effectively solve the layout problem of mixed-flow parallel production lines and reduce the idle energy consumption of machine tools during production. The proposed buffer configuration and layout design method can serve as a theoretical and practical reference for the layout design of mixed-flow parallel production lines.

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Abbreviations

Symbol:

Descriptions

b i :

Capacity of the i-th buffer

d mz, g mz (m):

Safe distance between equipment

e i :

Availability of the i-th equipment

k i :

Number of product categories of the i-th equipment

l, w (m):

Length and width of pallet or workpiece

m :

Number of equipment

n l, n w :

Number of columns and rows in the buffer

n d :

Number of workpieces produced by the parallel equipment

N 1 :

Number of workpieces that should reach the buffer area before equipment j starts processing

N 2 :

Number of workpieces processed when the number of workpieces in the buffer area in front of the equipment j reaches 0 again

P ij (W):

Processing energy consumption of the workpiece i on the equipment j

s i (m):

Minimum distance between equipment and wall

t d (h):

Processing time of each product

T I j (h):

No-load balancing time

W B k (m):

Maximum widths of the buffer of the k-th row

W j (kW/h):

Power of the equipment j

W L j (kW/h):

Standby power

Z mk :

Limit the rows where the work area is located

ρ i :

Failure rates of the i-th equipment

ω :

Weighting factor

C i :

Production cycle of the i-th equipment

D ij (m):

Manhattan distance matrix between equipment i and j

I jt (W):

Idle waiting energy consumption

L B, W B (m):

Length and width of the buffer

l m, w m (m):

Length and width of the m-th equipment

m i :

The i-th equipment

K :

Total number of rows

P SE (W):

Energy consumption for which the equipment j is turned on and off once

Q ij :

Logistics quantity between equipment i and j

S E jt (W):

Switch energy consumption

t ij (h):

Processing time of the workpiece i on the equipment j

T j (h):

Time for which the equipment j is turned on and off once

W m k (m):

Maximum widths of working area of the k-th row

W I jt (W):

Standby energy consumption

x m, y m :

Coordinate position of the m-th equipment

\(\mu_{i}\) :

Processing rate

\(\sigma_{i}\) :

Repair rates of the i-th equipment

\(\gamma\) :

Normalized parameter

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Acknowledgments

The authors gratefully acknowledge the financial support from the National Science and Technology Major Project of China (Grant No. 2019ZX04024001), the Natural Science Foundation of Beijing Municipality (Grant No.3192003), the General Project of Science and Technology Plan from Beijing Educational Committee (Grant No. KM201810005013), the Tribology Science Fund of State Key Laboratory of Tribology (Grant Nos.STLEKF16A02, SKLTKF19B08), and the Training Program of Rixin Talent and Outstanding Talent from Beijing University of Technology.

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Authors and Affiliations

  1. Institute of Advanced Manufacturing and Intelligent Technology, Beijing University of Technology, Beijing, 100124, People’s Republic of China

    Cai-Xia Zhang, Shu-Lin Dong, Hong-Yan Chu, Zhi-Feng Liu & Chong-Bin Yang

  2. Beijing Key Laboratory of Advanced Manufacturing Technology, Beijing University of Technology, Beijing, 100124, People’s Republic of China

    Cai-Xia Zhang, Shu-Lin Dong, Hong-Yan Chu, Zhi-Feng Liu & Chong-Bin Yang

  3. Beijing Xinghang Electromechanical Equipment Co., Ltd., Beijing, 100074, People’s Republic of China

    Guo-Zhi Ding & Shi-Yao Guo

  4. School of Mechanical Engineering and Automation, Beihang University, Beijing, 100191, People’s Republic of China

    Guo-Zhi Ding

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  1. Cai-Xia Zhang
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  2. Shu-Lin Dong
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Correspondence to Hong-Yan Chu.

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Zhang, CX., Dong, SL., Chu, HY. et al. Layout design of a mixed-flow production line based on processing energy consumption and buffer configuration. Adv. Manuf. 9, 369–387 (2021). https://doi.org/10.1007/s40436-021-00354-1

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  • DOI: https://doi.org/10.1007/s40436-021-00354-1

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