This study presents a new mathematical model for the design of reliable cellular manufacturing systems, which leads to reduced manufacturing costs, improved product quality and improved total reliability of the manufacturing system. This model is expected to provide a more noticeable improvement in time and solution quality in comparison with other existing models. Each part to be manufactured may select each of the predefined manufacturing routes, such that the total reliability of the system is increased. On the other hand, the model adopts to categorize the machines to determine the manufacturing cells (cell formation) and reduce the transportation costs. Thereby, both criteria of system reliability and manufacturing costs will be simultaneously improved. Due to the complexity of cell formation problems, a two-layer genetic algorithm is applied on the problem in order to achieve near optimal solutions. Furthermore, the performance of the proposed algorithm is shown for solving some computational experiments. Finally, the results of a practical study for designing a cellular manufacturing system as a case study in Iranian Diesel Engine Manufacturing Co., Tabriz, Iran are present.
Cellular manufacturing is considered as a lean technique of producing similar parts using sells or groups of team members, workstations, or equipment to facilitate operations by removing setup and unnecessary cost components among various operations. Cell formation and layout planning are the most components of the cellular manufacturing. This paper presents a dynamic method to minimize different costs including the total cost of movements within and between cells and exceptional parts. In this study, the Hierarchical Genetic Algorithm (HGA) is used for solving the resulted model and the results are compared with genetic algorithm. The results have indicated that the proposed method could reach optimal solutions for some small and medium sized problems in reasonable amount of time.
In this paper, a new robust approach is presented to handle demand uncertainty in cell formation and layout design process. Unlike the scenario based approaches, which use predefined scenarios to represent data uncertainty, in this paper, an interval approach is implemented to address data uncertainty for the part demands, which is more realistic and practical. The objective is to minimize the total inter- and intra-cell material handling cost. The proposed model gives machine cells and determines inter-and intra-cell layouts in such a way that the decision maker can control the robustness of the layout against the level of conservatism. An illustrative example is solved by CPLEX 10 to demonstrate the performance of the proposed method. The results reveal that when the level of conservatism is changed the optimal layout can vary, significantly.
Meta-heuristic approaches are general algorithmic framework, often nature-inspired and designed to solve NP-complete optimization problems in cellular manufacturing systems and has been a growing research area for the past two decades. This paper discusses various meta-heuristic techniques such as evolutionary approach, Ant colony optimization, simulated annealing, Tabu search and other recent approaches, and their applications to the vicinity of group technology/cell formation (GT/CF) problem in cellular manufacturing. The nobility of this paper is to incorporate various prevailing issues, open problems of meta-heuristic approaches, its usage, comparison, hybridization and its scope of future research in the aforesaid area.