Line feeding optimization for Just in Time assembly lines: an application to the automotive industry

International audienceThe performance of mixed-model assembly lines used in sectors such as the automotive industry depends on theavailability of a large number of components that have to be supplied to the line on time and at minimum cost. Insuch settings, components may have different features such as volume, weight, bill of material coefficient, etc.Additionally, a given component may have several alternative variants among which a single one is used in theassembly of end products. Each variant is thus characterized by a varying degree of usage rate. Hence, thediversity of parts requires the selection of the best assembly line feeding mode that aims at minimizing theaverage total operating cost which mainly consists of labor costs associated with parts preparation beforeassembly, transportation to the line, picking operations during assembly, as well as parts storage cost. This paperproposes an optimization model that assigns each individual component to the most efficient line feeding modeamong three alternatives which are line stocking, kitting and sequencing modes. The developed mixed integerprogram is applied to a first tier supplier plant in the automotive sector. Based on this model, insight is gained onthe trade-off to be considered when deciding the more appropriate line feeding mode for each individualcomponent and how system parameters impact this trade-off