Redundant configuration of automated flow lines based on “Industry 4.0”-technologies

Over the past decades, robots have been heavily used for flow lines to increase productivity and product quality and to relieve workers of repetitive and dangerous tasks. However, despite continuous improvement of robots, the occurrence of failures remains a significant challenge in the operation of automated flow lines. Due to the connection of the stations in a flow line via a material handling system, failures at one station can quickly lead to throughput losses due to blocking and starving of upstream and downstream stations, respectively. To some extent, these throughput losses can be reduced by installing buffers between the stations. However, the installation of buffers requires considerable investments and scarce factory space. Therefore, the minimization of the total number of buffers is one of the primary objectives in flow line planning. Due to the advances of manufacturing technologies that form the foundation of “Industry 4.0”, new solutions to reduce throughput losses caused by equipment failures open up. One solution is a redundant configuration, in which downstream stations automatically take over the operations of failed stations in the event of failure. The throughput loss in these situations mainly depends on the level of redundancy designed into the system. Based on existing methods for the design of automated flow lines, we present two line balancing formulations for the configuration of automated flow lines under consideration of redundancies. The first formulation aims at maximizing the lines’ level of redundancy. The second formulation aims at a balanced allocation of redundancies along the line. To evaluate the presented formulations, we compare the performance with an existing line balancing approach for automated lines. With respect to this approach, improvements of the throughput rate between 3 % and 7 % are achieved.