Abstract
For the design of manufacturing cells, numerous mathematical models and various algorithms have been extensively investigated in the literature. However, most of the proposed models and algorithms have more or fewer drawbacks on the issues with real-life situations. In this paper, we propose a mathematical model that incorporates multiple key real-life production factors simultaneously, namely, production volume, batch size, alternative process routings and perfect coefficient of each routing, cell size, unit cost of intercell/intracell movements, and path coefficient of material flows. Then, to solve this NP-hard model, we develop a heuristic algorithm with three stages: (1) form the temporary machine group plan according to the alternative process routings of each part, (2) select the appropriate process routing of each part with respect to the over-all material movement cost, and (3) configure the regular manufacturing cells based on the appropriate process routing. A simple numerical example and an industrial case are used to test the computational performance of the proposed algorithm. The test results imply that it is useful for manufacturing cell design in both quality and speed.
Similar content being viewed by others
References
Ham I, Hitomi K (1985) Group technology applications to production management. Kluwer-Nijhoff, Boston
Burbidge JL (1979) Group technology in engineering industry. Mech Eng, London
Wemmerlov U, Johnson DJ (1997) Cellular manufacturing at 46 user plants: implementation and performance improvements. Int J Prod Res 35:29–49
Balakrishnan J, Cheng CH (2007) Multi-period planning and uncertainty issues in cellular manufacturing: a review and future directions. Eur J Oper Res 177:281–309
Reisman A, Kumar A, Motawani J, Cheng CH (1997) Cellular manufacturing: a statistical review of the literature (1965–1995). Oper Res 45(4):508–520
Wei JC, Gaither N (1990) A capacity constrained multiobjective CF method. J Manuf Sys 9:222–232
Selim HM, Askin RG, Vakharia AJ (1998) Cell formation in group technology: review, evaluation and direction for future research. Comput Ind Eng 34:3–20
Mansouri SA, Husseini SM, Newman ST (2000) A review of the modern approaches to multi-criteria cell design. Int J Prod Res 38:1201–1218
Yin Y, Yasuda K (2006) Similarity coefficient methods applied to the cell formation problem: a taxonomy and review. Int J Prod Econ 101:329–352
Defersha FM, Chen M (2006) A comprehensive mathematical model for the design of cellular manufacturing systems. Int J Prod Econ 103:767–783
Greene T, Sadowski R (1984) A review of cellular manufacturing assumptions, advantages, and design techniques. J Oper Manag 4:85–97
Joines J, Culbreth C, King R (1996) A comprehensive review of production oriented cell formation techniques. Int J Fact Auto Info Manag 3:225–265
Goncalves JF, Resende MGC (2004) An evolutionary algorithm for manufacturing cell formation. Comput Ind Eng 47:247–273
Askin RJ, Vakharia AJ (1990) Group technology-cell formation and operation. In: Cleland DI, Bidanda B (eds) Automated factory handbook: technology and management. TAB, New York, pp 317–366
McAuley J (1972) Machine grouping for efficient production. Prod Eng 51:53–57
Stanfel L (1985) Machine clustering for economic production. Eng Costs Prod Econ 9:73–81
Gupta T, Seifoddini H (1990) Production data based similarity coefficient for machine-component grouping decisions in the design of a cellular manufacturing system. Int J Prod Res 28:1247–1269
Khan M, Islam S, Sarker B (2000) A similarity coefficient measure and machine-parts grouping in cellular manufacturing systems. Eng Costs Prod Econ 38:699–720
Yasuda K, Yin Y (2001) A dissimilarity measure for solving the cell formation problem in cellular manufacturings. Comput Ind Eng 39:1–17
Srinivasan G, Narendran TT (1991) GRAFICS-a nonhierarchical clustering-algorithm for group technology. Int J Prod Res 29:463–478
Chandrasekharan MP, Rajagopalan R (1987) ZODIACan algorithm for concurrent formation of part families and machine cells. Int J Prod Res 25:835–850
Nair GJ, Narendran TT (1998) CASE: a clustering algorithm for cell formation with sequence data. Int J Prod Res 36:157–179
Nair GJ, Narendran TT (1998) ACCORD: a bi-criterion algorithm for cell formation using ordinal and ratio-level data. Int J Prod Res 37:539–556
Miltenburg J, Zhang W (1991) A comparative evaluation of nine well-known algorithms for solving the cell formation in group technology. J Oper Manag 10:44–72
Rajagopalan R, Batra JL (1975) Design of cellular production systems—a graph theoretic approach. Int J Prod Res 13:567–579
Askin RG, Cresswell SH, Goldberg JB, Vakharia AJ (1991) Hamiltonian path approach to reordering the part-machine matrix for cellular manufacturing. Int J Prod Res 29:1081–1100
Mukhopadyay SK, Ramesh BK, Vijai SKV (2000) Modified Hamiltonian chain: a graph theoretic approach to group technology. Int J Prod Res 38:2459–2470
Srinivasan G (1994) A clustering algorithm for machine cell formation in group technology using minimum spanning trees. Int J Prod Res 32:2149–2158
Ng S (1993) Worst-case analysis of an algorithm for cellular manufacturing. Euro J Oper Res 69:384–398
Ng S (1996) On the characterization and measure of machine cells in group technology. Oper Res 44:735–744
Askin RG, Chiu KS (1990) A graph partitioning procedure for machine assignment and cell formation in group technology. Int J Prod Res 28:1555–1572
Kusiak A (1987) The generalized group technology concept. Int J Prod Res 25:561–569
Boctor F (1991) A linear formulation of the machine-part cell formation problem. Int J Prod Res 29:343–356
Choobineh F (1988) A framework for the design of cellular manufacturing systems. Int J Prod Res 26:1161–1172
Co HC, Araar A (1988) Configuring cellular manufacturing systems. Int J Prod Res 26:1511–1522
Vakharia A, Chang Y (1997) Cell formation in group technology: a combinatorial search approach. Int J Prod Res 35:2025–2043
Steudel H, Ballakur A (1987) A dynamic programming based heuristic for machine grouping in manufacturing cell formation. Comput Ind Eng 12:215–222
Shafer SM, Rogers DF (1991) A goal programming approach to the cell formation problem. J Oper Manag 10:28–43
Venugopal V (1999) Soft-computing-based approaches to the group technology problem: a state-of-the-art review. Int J Prod Res 37:3335–3357
Basu A, Hyer N, Shtub A (1995) An expert system based approach to manufacturing cell design. Int J Prod Res 33:2739–2755
ElMaraghy HA, Gu P (1988) Knowledge-based system for assignment of parts to machines. Int J Adv Manuf Technol 3:33–44
Moon YB (1990) Forming part-machine families for cellular manufacturing: a neural network approach. Int J Adv Manuf Technol 5:278–291
Kusiak A, Chung Y (1991) GT/ART: using neural networks to form machine cells. Manuf Rev 4:293–301
Moon YB, Chi SC (1992) Generalized part family formation using neural network techniques. J Manuf Syst 11:149–159
Venugobal V, Narendran TT (1994) Machine-cell formation through neural network models. Int J Prod Res 32:2105–2116
Ahmed P, Moghaddam TR, Safaei N (2004) A comparison of heuristic methods for solving a cellular manufacturing model in a dynamic environment. Working Paper WP007/04, University of Wolverhampton
Holland JH (1975) Adaptation in natural and artificial systems. University of Michigan Press, Ann Arbor
Gupta Y, Gupta M, Kumar A, Sundram C (1995) Minimizing total inter-cell and intera-cell moves in cellular manufacturing: a genetic algorithm. Int J Comput Integr Manuf 8:92–101
Joines J, Culberth C, King R (1996) Manufacturing cell design: an integer programming model employing genetic algorithms. IIE Trans 28:69–85
Venugopal V, Narendran T (1992) A genetic algorithm approach to the machine component grouping problem with multiple objectives. Comput Ind Eng 22:469–480
Gen M, Cheng R (1997) Genetic algorithms and engineering design. Wiley, New York
Wu X, Chu CH, Wang Y, Yan W (2006) A genetic algorithm for cellular manufacturing design and layout. Eur J Oper Res 181:156–167
James TL, Brown EC, Keeling KB (2007) A hybrid grouping genetic algorithm for the cell formation problem. Comput Oper Res 34:2059–2079
Glover F (1989) Tabu search: part I. ORSA J Comput 1:190–206
Glover F (1990) Tabu search: part II. ORSA J Comput 2:4–32
Logendran R, Ramakrishna P, Srikandarajah C (1994) Tabu search based heuristic for cellular manufacturing systems in the presence of alternative process plans. Int J Prod Res 32:273–297
Lozano S, Adenso-Diaz B, Onieva L (1999) A one-step Tabu search algorithm for manufacturing cell design. J Oper Res Soc 50:509–516
Cao D, Chen M (2004) Using penalty function and Tabu search to solve cell formation problems with fixed cell cost. Comput Oper Res 31:21–37
Schaller J (2005) Tabu search procedures for the cell formation problem with intra-cell transfer costs as a function of cell size. Comput Ind Eng 49:449–462
Boctor FF (1991) A linear formulation of the machine-part cell formation problem. Int J Prod Res 29:343–356
Chen M (1998) A mathematical programming model for systems reconfiguration in a dynamic cellular manufacturing environment. Ann Oper Res 77:109–128
Sofianopoulou S (1997) Application of simulated annealing to a linear model for the formulation of machine cells in group technology. Int J Prod Res 35:501–511
Vakharia A, Chang Y (1997) Cell formation in group technology: a combinatorial search approach. Int J Prod Res 35:84–97
Wang TY, Wu KB, Liu YW (2001) A simulated annealing algorithm for facility layout problems under variable demand in cellular manufacturing systems. Comput Ind 46:181–188
Xambre AR, Vilarinho PM (2003) A simulated annealing approach for manufacturing cell formation with multiple identical machines. Eur J Oper Res 151:434–446
Sofianopoulou S (1999) Manufacturing cells design with alternative process plans and/or replicate machines. Int J Prod Res 29:463–479
Uddin MK, Shanker K (2002) Grouping of parts and machines in presence of alternative process routes by genetic algorithm. Int J Prod Econ 76:219–228
Won Y, Lee KC (2001) Group technology cell formation considering operation sequence and production volume. Int J Prod Res 39:2755–2768
Vakharia AJ, Wemmerlov U (1990) Designing a cellular manufacturing system: a materials flow approach based on operation sequences. IIE Trans 22:84–97
Onwubolu GC, Mutingi M (2001) A genetic algorithm approach to cellular manufacturing systems. Comput Ind Eng 39:125–144
Heragu SS, Chen JR (1998) Optimal solution of cellular manufacturing system design: benders decomposition approach. Eur J Oper Res 107:175–192
Adil GK, Rajamani D (2001) The trade-off between intracell and intercell moves in group technology cell formation. J Manuf Syst 19:305–317
Yin Y, Yasuda K (2002) Manufacturing cells design in consideration of various production factors. Int J Prod Res 40:885–906
Gupta T (1993) Design of manufacturing cells for fliexible environment considering alternative routeing. Int J Prod Res 31:1259–1273
Yasuda K, Hu L, Yin Y (2005) A grouping genetic algorithm for the multi-objective cell formation problem. Int J Prod Res 43:829–853
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Liu, C., Yin, Y., Yasuda, K. et al. A heuristic algorithm for cell formation problems with consideration of multiple production factors. Int J Adv Manuf Technol 46, 1201–1213 (2010). https://doi.org/10.1007/s00170-009-2170-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-009-2170-0