Designing efficient line feeding systems for low-volume, high-variety manufacturing

Designing an efficient and effective line feeding system is crucial for manufacturing facilities operating in low-volume, high-variety mass customisation environments. Shorter takt times, which drive operational performance, combined with limited space at the border of line, have led to the development of advanced line feeding policies to ensure timely and accurate part delivery. Low-volume, high-variety systems typically require large numbers of different components and complex sets of constraints to be accurately modelled. This paper proposes a comprehensive, integrated mixed integer programming model for the strategic assembly line feeding problem. The goal of this problem is to optimise line feeding system design by jointly determining the placement and sizing of preparation cells, along with selecting and sizing vehicle fleets for various line feeding policies. The proposed model explicitly captures the interdependencies among these key components, offering a more realistic and comprehensive decision-support framework. Its effectiveness is evaluated using a diverse set of real-world inspired instances, showcasing both the feasibility and the benefits of integrated decision-making.