A genetic algorithm for the inter-cell layout and material handling system design

Abstract

The traditional optimization processes for the cell system layout (CSL) and material handling system in cellular manufacturing systems (CMSs) were carried out sequentially and separately. The solutions obtained by this means can be far from the total optimum. In this paper, an integrated approach to the problem is proposed that attempts to design CSL and flow path structure simultaneously. The cells in question are assumed to be shape-fixed and have pre-determined pickup/delivery (P/D) stations. A sequence-pair based CSL-generating algorithm allows cells to be placed at any possible position on a continuous floor plan and leads to a corresponding feasible CSL. A grid graph for the CSL is accordingly constructed to provide possible flow paths for the layout. Then, the sum of the traveling distances, determined by the shortest path algorithm, is used to evaluate the CSL. These steps are embedded into a genetic algorithm (GA) that searches the solution space to obtain optimal layouts based on the contour distances between the P/D stations. Computational results demonstrate that the run time required to solve the test problems is quite acceptable given the long-term nature of facility layout decisions. Moreover, a comparison of the computational results with the existing methods indicates that the proposed approach is a viable alternative for effectively generating layout designs for CMS.