Deterministic and dynamic solution approach for welds reallocation due to robot's failures

Roey Rosenberg*, Yossi Bukchin, Irad Ben-Gal

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review


One of the main problems of spot welding in automotive assembly lines is the failure of welding robots. A possible solution in such a case is the reallocation of the welding spots from the failed robot(s) to a backup robot(s) during the repair period. To this end, an optimal recovery plan in terms of the throughput loss has to be determined under various operational constraints. In a previous research, a MILP formulation solution approach was suggested to solve backup allocation problem. Here, we extend the previous work and consider: (1) higher resolution of the work content, (2) enhanced precedence constraints, (3) the required setup time when breaking weld groups and (4) some optional configuration constraints. In addition, the stochastic aspect of the problem is addressed, and a dynamic mathematical model is developed and solved via Markov Decision Process (MDP) formulation. Experiments demonstrate the advantages of the proposed approaches.

Original languageEnglish
Title of host publicationProceedings of the 13th IFAC Symposium on Information Control Problems in Manufacturing, INCOM'09
PublisherIFAC Secretariat
Number of pages6
EditionPART 1
ISBN (Print)9783902661432
StatePublished - 2009

Publication series

NameIFAC Proceedings Volumes (IFAC-PapersOnline)
NumberPART 1
ISSN (Print)1474-6670


  • Algorithms
  • Automotive
  • Optimization
  • Robotics


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