Simulation-based layout optimization for multi-station assembly lines

This article presents a novel approach for the automated 3D-layout planning of multi-station assembly lines. The planning method is based on a comprehensive model of the used production resources, including their geometry, kinematic properties, and general characteristics. Different resource types can be included in the planning system. A genetic algorithm generates and optimizes possible layouts for a line. The optimization aims to minimize the line’s area and the costs for assembling the line while simultaneously optimizing the resources’ positioning to perform their tasks. The line’s cycle time is considered as a boundary condition. For the evaluation of different layout alternatives, a multi-body simulation is performed. A parameter study is used to set the algorithm’s parameters. Afterward, the algorithm is applied to three increasingly complex examples to validate and evaluate its functionality. The approach is promising for industrial applications as it allows the integration of various resource types and individualization of the optimization function.