Dynamic Cellular Manufacturing Systems Design - a Comprehensive Model & Hhga

Today’s product demand and mix changes requiring reconfiguration of cells in each period of a multi-period planning horizon, This paper proposes a mixed-integer non-linear programming model for reconfigurable CMS design to meet changes in product mix & demand in each period of a multi-period planning horizon. The proposed model, to the best of author’s knowledge, is the most comprehensive model to date with more integrated approach. The proposed DCMS model integrates concurrently the important manufacturing attributes in existing models in a single model such as machine breakdown effect machine repair & production time loss cost; production planning part inventory holding, internal production cost & outsourcing cost; Process batch size; transfer batch sizes for intra-cell travel & inter-cell travel; lot splitting; alternative process plan & routing, sequence of operation; multiple copies of identical copies; machine capacity, cutting tooling requirements, work load balancing, machine in different or same cell constraint; machine procurements, multiperiods dynamic cell reconfiguration . It also includes various costs. A Hybrid Hierarchical Genetic Algorithm (HHGA) is also designed to solve the model for some examples taken from existing literature. Our experience shows that HHGA needs much less computational time than LINGO-based solution approach. Further, we intend to enhance the model with attributes such as production control, selection of material handling equipment and equipment layout etc. As a practical application of this work, the academician, the designer and managers of cellular manufacturing systems will find this work useful for design/ redesign of cells in their plants or research work.