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X
N
i1
TP
i,j
for all j 1, 2 . . . m
T
X
M
i1
TAP
j
/ m
T
Proposed method
Step 0
Obtain the workstation with workload considered to be bottleneck.
bj TAP
J
=
T
Find all workstations that b
j
$ 1, insert them into a set {B},
Stage I: Initialization. Insert all workstations into a set {AM}, and insert all parts
into a set {AP}
Set C(K) {0}, Set P(K) {0}, and Set AL(K) {0} for k 1, 2, . . ., K
Step 1
Set K 1, to initialize the formation of rst MC center.
Step 2
Select the smallest value of TAP
j
as an initial network node for the kth group, call it the
seed workstation or machine (M). Insert Ms into C(K) set.
Step 3
Branch all parts that visit seed machine Ms. Insert all parts into P(K) set.
Step 4
Bound every part which does not require another machine. Otherwise, branch to a new
machine required to be visited. Insert the new machines into C(K) set.
Step 5
Calculate the workload of the kth MC cell, CL(K).
If the CL(K) , MWL, continue step 6.
If the CL(K) . MWL, then delete parts in P(K) until CL(K) become less than MWL.
Go to step 8.
Step 6
Bound every machine that belongs to set {B} machine. Branch all parts that visit all
the remaining machines in set C(K).
Step 7
Calculate the used workload of the kth MC, UWL(K).
If the UWL(K) , MWL, repeat step 6.
If the UWL(K) . MWL, then do not insert parts in the previous step and go to step 8.
Cellular
manufacturing
systems
185
Step 8
Calculate the remaining workload, RWL(K) of the kth MC.
Step 9
Insert all parts that can be completed by the machines that are already assigned to the
C(K) into set AL(K) as an alternative list.
Step 10
Calculate the alternative parts, which could be nished in the kth MC, AWL(K)
If UWL(K) AWL(K) , TAP, then insert all parts from A(K) into C(K)
If UWL(K) AWL(K) . TAP, then do nothing.
Step 11
Form MC cells from all machines in a closed network C(K). Use a closed network to
form a family of parts P(K) and alternative parts AL(K).
The suggestion is to keep the track of the workload at every single step for the
remaining jobs and workstations only. Thus, create a new two dimensional table for
the remaining jobs in{AP} and workstations {AM}.
Step 12
Delete all parts in P(K) from set {AP}.
Step 13
Calculate new TAP
j
.
Step 14
Delete all machines with TAP
j
0 from set {AM}.
Step 15
Create a new two-dimensional table for the remaining jobs in{AP} and workstations
{AM}.
Step 16
Increment K by one
Stage II next. Second MCM formation, go to step 1 and continue to step 16.
Stage III next. Third MCM formation, go to step 1 and continue to step 16.
Step 17
STOP Criteria when all parts produced either direct assignment into cell at the rst
formation of the cell or assigned as alternative to balance the workload among MC.
Industrial application
To demonstrate the merit of the proposed method, a practical problem from an
industrial partner is used. The unit consists of 43 different components, out of which,
31 components are being manufactured using 12 different workstation centers. Each
part is considered as a job order, which includes many operations where each operation
takes a certain operation time. The processing time for each operation in the
corresponding workstation is given in Table I. The present plant has highly congested
JMTM
16,2
186
movement and WIP. Using this method will transform the single plant into multiple
cellular manufacturing centers. The proposed method ensures better scheduling and
the close to optimum job sequence. The objective of this work is to design
manufacturing cell with workload balance among all MCM cells.
Assumption to choose the value of K, the number of cells
(1) The criterion for selecting the minimum value of K:
K
max{TAP
j
}
MWL
The maximum value of TAP
j
is then divided by MWL, the number of hours per
week a machine has to run. As shown in the table, the maximum number of
hours is 103 and the number of working hours is 35/week. Therefore:
Max {TAP
j
} /MWL103/35 2.94.
Rounding off this value to the next higher integer value gives value of K 3.
Part ws1 ws2 ws3 ws4 ws5 ws6 ws7 ws8 ws9 ws10 ws11 ws12 TP
j
1 3 0 3 2 0 11 0 0 0 7 0 0 26
2 5 0 3 0 4 0 0 0 0 0 0 3 15
3 8 4 4 5 3 0 0 0 0 0 0 4 28
4 0 3 0 6 0 0 0 0 7 0 0 0 16
5 0 3 0 0 0 6 5 0 7 0 0 7 28
6 4 3 0 5 0 0 0 0 0 6 3 0 21
7 6 0 6 0 6 0 0 0 0 0 0 8 26
8 0 5 0 0 0 0 0 3 0 0 0 5 13
9 0 6 0 0 0 0 0 3 4 0 0 0 13
10 7 4 0 8 0 0 5 0 4 0 0 6 34
11 0 0 7 0 7 6 0 0 0 0 0 0 20
12 0 3 0 0 0 0 7 0 0 9 3 9 31
13 3 0 0 0 0 0 0 0 0 0 0 0 3
14 4 0 0 0 6 0 0 0 0 0 3 0 13
15 5 2 4 0 0 9 0 7 0 0 0 0 27
16 6 0 0 12 0 0 0 0 0 0 0 0 18
17 0 2 0 0 0 0 0 0 0 0 0 9 11
18 2 2 0 0 9 0 0 0 0 0 2 0 15
19 7 0 1 6 0 0 0 0 0 0 0 2 16
20 8 2 1 0 0 4 0 0 8 0 0 0 23
21 0 7 0 12 12 0 0 0 0 0 0 0 31
22 14 0 12 0 0 0 0 0 0 0 0 0 26
23 3 4 0 0 0 0 0 5 0 0 0 0 12
24 0 0 0 0 11 0 0 0 6 0 0 0 17
25 3 3 9 0 0 0 7 0 0 8 0 0 30
26 0 0 5 7 0 0 0 0 0 0 0 0 12
27 0 3 0 0 8 0 0 7 0 0 0 0 18
28 3 0 0 9 0 9 0 0 0 0 0 0 21
29 2 3 5 0 7 0 0 0 0 0 0 0 17
30 3 0 0 3 0 4 0 0 4 0 0 7 21
31 7 5 0 0 8 0 0 0 0 0 0 0 20
TP
j
103 64 60 75 81 49 24 25 40 30 11 60 622
Table I.
Processing time of 31
parts on 12 workstations
Cellular
manufacturing
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(2) The criterion for selecting the maximum value of K:
The maximum value of K is obtained by dividing the total processing time
by the maximum value of T
j
:
K
X
m
i1
X
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TP
i;j
MaxTAP
j