Abstract
This mathematical model forms machine cells, optimises the costs of unassigned machines and components, and designs the shop floor cell layout to have minimal movement of materials. The complete similarity measure algorithm forms machine cells and part families in a refined form. Later, exceptional elements are eliminated in the optimisation model by using machine duplication and sub-contracting of parts. Then the shop floor layout is designed to have optimised material movements between and within cells. An evaluation of the cell formation algorithm’ performance is done on the benchmark problems of various batch sizes to reveal the process’s capability compared with other similar methods. The data of machining times are acquired and tabulated in a part incidence matrix, which is used as input for the algorithm. The results from the linear programming optimisation model are that costs are saved, machines are duplicated, parts are sub-contracted, and there are inter- and intra- cellular movements. Finally, the output of the inbound facility design is the floor layout, which has machine cell clusters within the optimised floor area.
Highlights
Cellular manufacturing (CM) works to increase productivity and production efficiency by reducing processing time, work-in-progress, and material movement time
Percentage of exceptional elements: Several elements that occur out of the diagonal blocks are called exceptional elements, which denote the impact of cell formation
The outcomes obtained from this layout design are the floor area required by each cell and savings in the floor area compared with the traditional process layout, and the distances travelled by each job in and between cells and the savings in distances travelled compared with the process layout
Summary
Cellular manufacturing (CM) works to increase productivity and production efficiency by reducing processing time, work-in-progress, and material movement time. In a CM system, identical components are formed as families and related machines are formed as cells so that one part family can be manufactured within a machine cell. The cell formation will have exceptional elements (EE) i.e., exceptional machines and parts. EE creates interactions between two manufacturing cells and void elements (VE) inside block diagonals that affect machine utilisation and grouping efficiency. An exceptional component is a component that requires manufacturing on machines in two or more cells. An exceptional machine manufactures parts from two or more part families. Exceptional elements create inter-cellular movements that affect the independence of the cells and increase costs
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