Solving the car resequencing problem with mix banks

Abstract

Mixed-model assembly lines are used at the automotive industry to obtain more efficient production flows. The sequencing of the different units is done at the very beginning of the process, but frequently large perturbations of the original sequence can be observed. These perturbations might be intended or not but to some extent, a resequencing process -to create a new sequence with the available unts- is necessary. This paper focuses in the re-sequencing process by using parallel buffering lines (known as mix banks). Algorithms to decide the line of destination of incoming units and the line of extraction of units to the line are presented and evaluated. The algorithms and their performance have been verified using discrete event simulation software (SIMIO). An analysis considering different operations situations is done and some recommendations to real case users are presented.