Modelling and simulation analysis of process alternatives in the cellular manufacturing of axially symmetric parts

Abstract

This paper highlights the issues of multi-stage process planning within facilities of definite processing capabilities, under the consideration of multiple choices of process routings. The process alternative based on operation concentration, accomplished by integrating burnishing into machining operations, is compared to a process with operation differentiation, assuming part finishing in separate grinding operations. A modelling approach to manufacturing knowledge representation, an average linkage clustering procedure of defined machine capability patterns and a set of validation criteria are proposed to enable the cellular decomposition of the facilities and optimum part flow allocation. Simulation investigations of alternative process flows have been performed using stochastic type models and data sets derived from industrial practice. The investigations show the distinct prevalence of the design solutions with operation concentration in terms of assumed performance measures. The results of this work indicate the practical usability of the developed modelling framework applied to exploring the total operational issues of cellular flexible manufacturing systems (FMSs).