This study presents a new mathematical model for the design of reliable cellular manufacturing systems, which leads to reduced manufacturing costs, improved product quality and improved total reliability of the manufacturing system. This model is expected to provide a more noticeable improvement in time and solution quality in comparison with other existing models. Each part to be manufactured may select each of the predefined manufacturing routes, such that the total reliability of the system is increased. On the other hand, the model adopts to categorize the machines to determine the manufacturing cells (cell formation) and reduce the transportation costs. Thereby, both criteria of system reliability and manufacturing costs will be simultaneously improved. Due to the complexity of cell formation problems, a two-layer genetic algorithm is applied on the problem in order to achieve near optimal solutions. Furthermore, the performance of the proposed algorithm is shown for solving some computational experiments. Finally, the results of a practical study for designing a cellular manufacturing system as a case study in Iranian Diesel Engine Manufacturing Co., Tabriz, Iran are present.
The concept of virtual cellular manufacturing system (VCMS) is finding acceptance among researchers as an extension to group technology. In fact, in order to realize benefits of cellular manufacturing system in the functional layout, the VCMS creates provisional groups of resources (machines, parts and workers) in the production planning and control system. This paper develops a mathematical model to design the VCMS under a dynamic environment with a more integrated approach where production planning, system reconfiguration and workforce requirements decisions are incorporated. The advantages of the proposed model are as follows: considering the operations sequence, alternative process plans for part types, machine timecapacity, worker time‐capacity, cross training, lot splitting, maximal cell size, balanced workload for cells and workers. An efficient linear programming embedded particle swarm optimization algorithm is used to solve the proposed model. The algorithm searches over the 0‐1 integer variables and for each 0‐1 integer solution visited; corresponding values of integer variables are determined by solving a linear programming sub‐problem using the simplex algorithm. Numerical examples show that the proposed method is efficient and effective in searching for near optimal solutions.
In a closed-loop supply chain network, the aim is to ensure a smooth flow of materials and attaining the maximum value from returning and end-of-life goods. This paper presents a single-objective deterministic mixed integer linear programming (MILP) model for the closed-loop supply chain (CLSC) network design problem consisting of plants, collection centers, disposal centers, and customer zones. Our model minimizes the total costs comprising fixed opening cost of plants, collection, disposal centers, and transportation costs of products among the nodes. As supply chain network design problems belong to the class of NP-hard problems, a novel league championship algorithm (LCA) with a modified priority-based encoding is applied to find a near-optimal solution. New operators are defined for the LCA to search the discrete space. Numerical comparison of our proposed encoding with the existing approaches in the literature is indicative of the high quality performance of the proposed encoding.
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