Mathematical Model for Proactive Resequencing of Mixed Model Assembly Lines

Mixed model assembly lines are state of the art for automotive mass production. In the context of mass customization and individualization the car sequencing recently became more and more challenging due to varying assembly tasks and processing times. Classical principles such as the vehicle pearl chain are thus reaching their limits. Therefore, planned changes in the vehicle sequence during final assembly, Proactive Resequencing, was proposed to optimize utilization segment by segment. The concept leads to a long-term buffer planning problem on a strategic level as well as to an adapted vehicle sequencing problem with enhanced flexibility on an operative level. This paper introduces a mathematical model for the combined buffer planning and order sequencing problem for automotive assembly lines. It also outlines a solution approach for the mentioned production planning challenges separated by their timing preferences. (C) 2019 The Authors. Published by Elsevier B.V.