Application of mixed-integer linear programming in a car seats assembling process

Abstract

In this paper, a decision problem involving a car parts manufacturing company is modeled in order to prepare the company for an increase in demand. Mixed-integer linear programming was used with the following decision variables: creating a second shift, purchasing additional equipment, determining the required work force, and other alternatives involving new manners of work distribution that make it possible to separate certain operations from some workplaces and integrate them into others to minimize production costs. The model was solved using GAMS. The solution consisted of programming 19 workers under a configuration that merges two workplaces and separates some operations from some workplaces. The solution did not involve purchasing additional machinery or creating a second shift. As a result, the manufacturing paradigms that had been valid in the company for over 14 years were broken. This study allowed the company to increase its productivity and obtain significant savings. It also shows the benefits of joint work between academia and companies, and provides useful information for professors, students and engineers regarding production and continuous improvement. © 2011 Bralizian Operations Research Society.