ERGONOMİK MONTAJ HATTI DENGELEME PROBLEMİNE FARKLI ÇOK AMAÇLI ÇÖZÜM YAKLAŞIMLARI

Montaj hattı dengeleme problemlerinde (MHDP) istasyon sayısı, çevrim zamanı gibi ekonomik kısıtların yanında gerçekleştirilen görevler nedeniyle oluşabilecek zorlanmalardan kaynaklanan riskler dikkate alınmalıdır. Çünkü montaj istasyonlarında tekrarlı işler ve bu işler esnasında sergilenen statik çalışma duruşları Kas İskelet Sistemi Rahatsızlıklarının (KİSR) oluşmasına yol açmaktadır. Bu durum çalışanların ve dolayısıyla montaj hatlarındakiişgücü verimliliğini olumsuz etkilemektedir. Bu çalışmada istasyonun çevrim zamanını ve istasyonların ergonomik risk skorundan pozitif sapmalarının toplamını enküçükleyen iki amaçlı bir matematiksel model geliştirilmiştir. Önerilen çok amaçlı modelin çözümünde, ağırlıklı toplam, konik skalerleştirme, epsilon kısıt ve melez yöntemleri uygulanmıştır. Bu yöntemler karşılaştırılarak her bir yöntemde elde edilen pareto noktalar incelenmiştir. Geliştirilen modelin gerçek hayat uygulaması bir beyaz eşya fabrikasında gerçekleştirilmiştir. Toplam 32 istasyon, 78 iş elemanından oluşan tek modelli basit montaj hattında Hızlı Tüm Vücut Değerlendirme (Rapid Entire Body Assessment-REBA) analizi yapılarak çalışma duruşlarına ilişkin ergonomik risk skorları belirlenmiştir. Montaj hattından günlük elde edilmek istenen çıktı miktarına göre çevrim süresi 41 saniye olarak belirlenmiştir. Model ve çözüm yöntemleri The General Algebraic Modelling System(GAMS) programında kodlanarak çözdürülmüş ve sonuçlar elde edilmiştir. Konik Skalerleştirme Yöntemi ergonomik MHDP’ de ilk kez kullanılmış böylece, klasik çözüm yöntemlerinin tarayamadığı çözüm alanlarında farklı pareto çözümler elde edilmiştir. Ergonomik riskler dikkate alınarak elde edilen çözümlerde yüksek riskli istasyon sayısında azalma olduğu görülmüştür.

DIFFERENT MULTI-OBJECTIVE SOLUTION APPROACHES TO THE ERGONOMIC ASSEMBLY LINE BALANCING PROBLEM

In assembly line balancing problems (ALBP), beside technological constraints such as the number of stations and cycle time as well as the strain loads that may occur due to operations should also be taken into account. Because repetitive works in assembly stations and static body postures during these works cause Musculoskeletal Disorders (WMSD) and thus negatively affect the productivity and efficiency of the workers and therefore the assembly lines. In this study, a two-objective mathematical model has been developed that minimizes the cycle time and the sum of positive deviations from the ergonomic risk score of the stations. In the solution of the multi-objective model, weighted sum, conical scalarization, epsilon constraint and hybrid methods are applied. By comparing these methods, pareto points obtained in each method were examined. The real life application of the developed model was realized in a home-appliance factory. REBA (Rapid Entire Body Assessment) analysis was performed on a single-model assembly line consisting of 32 stations and 78 operations, and ergonomic risk scores for working postures were determined. The cycle time is determined as 41 seconds, depending on the amount of daily outputdesired to be obtained from the assembly line. Model and solution methods were coded in GAMS program and results were given. Conical Scalarization method is used for the first time in ergonomic ALBP, and different pareto solutions have been obtained in the solution areas that classical solution methods cannot scan. Considering the ergonomic risks, it has been observed that there is a decrease in the number of high-risk stations in the solutions.

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