Cell formation and layout design for multiple-cell manufacturing with flexible processing and routing

Ying-Chin Ho, Purdue University

Abstract

This research addresses the cell formation and layout design problems of manufacturing systems having two key characteristics: flexible processing/routing and multiple cells. Recent simulation studies indicate that systems with these flexibilities yield better performance than systems with fixed processes and routes. Cellular manufacturing is also proving very effective and many companies currently have multiple-cell systems. In spite of these findings, many of the current design techniques continue to be developed for single cell and/or fixed processing and routing systems. Many of the challenges in this study result from allowing choices in processes and routes. When alternative processing is considered for each part, standard cell formation techniques cannot be applied. Likewise, when alternative routings are allowed, specific flow matrices are no longer available. We address the cell formation problems with an operation-based similarity measure which considers the manufacturing process in more detail and can handle both traditional and more complicated flexible problems. A part grouping procedure iteratively produces improving part groups by minimizing inter-cell flow, and an allocation model generates a cost-effective assignment of machines to part groups and operations to alternative machines. An integrated layout design module has been proposed. Machine layout, cell layout, cell input/output location, and within-cell flow path position problems have been investigated. The proposed layout procedures emphasize accurate flow distance calculations, simultaneous layout of facilities and flow paths, and characteristics of flow paths. Techniques have been proposed to overcome the lack of specific flow matrices. A verification and re-design module is proposed to validate the feasibility and performance of the proposed design. This module simulates the proposed design, monitors its performance, detects design problems, and re-designs the system whenever necessary. Various techniques have also been proposed to ensure the consistency and integration between design modules. Rigorous testing of the proposed solution techniques ensures solution quality. Coupled with the proposed design techniques, our experiments show that the proposed design procedure produces a multiple-cell system with highly satisfactory results.

Degree

Ph.D.

Advisors

Moodie, Purdue University.

Subject Area

Industrial engineering

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