An optimization grouping method in a multi-line manufacturing system

Abstract

A tailored product grouping method using binary integer linear program for optimization is developed for two production lines in a food packaging manufacturer. A mathematical model is created to assign products to the two dedicated production lines with an objective to minimize the total setup times. The optimization model is subject to capacity constraints on each line. With the demand of each product entered, the model is able to generate an optimal production grouping and sequence as well as the minimal total setup time required. Compared with CAS current fixed grouping method, this linear program grouping method reduces total setup time generally by 17% and prevents both production lines from overloading. Also, this grouping method allows the Make-to-Order food packaging manufacturer to respond to changes in demand volume and product mix by changing the product grouping accordingly.