Integrated cell formation and layout problem considering multi-row machine arrangement and continuous cell layout with aisle distance

Abstract

Cellular manufacturing is an important application of group technology and the cell formation process is one of the important steps in designing cellular manufacturing system. In recent years, researchers have noticed potential benefits when the layout problem is considered within the cell formation process. Nevertheless, there are not sufficient studies about consideration of real-life features in the cell formation and layout design process. In this paper, a new approach is presented to integrate the cell formation and its layout design. The proposed approach has three important design features not found in other papers. These design features are multi-row intra-cell layout (layout of machines within the cells), continuous inter-cell layout (layout of rectangular shape cells on the planar area), and aisle distance. The objective of the proposed approach is to form machine cells, find the layout of machine cells, and obtain the arrangement of machines within the cells such that the total material handling cost is minimized. In order to have a more accurate layout design, the material handling cost is calculated in terms of the actual position of machines within the cell. Due to the computational complexity of the proposed problem, a heuristic method is proposed to solve medium-and large-scale problems in a reasonable computational time. Three lower bounds are developed for the proposed integrated problem in which the tightest of them is chosen for evaluating the solution of the heuristic method. Finally, numerical examples adopted from the literature are solved to verify the performance of the proposed heuristic method and illustrate the advantages of the proposed integrated approach. The results indicated that the heuristic method is both effective and efficient in solving real-sized problems. The results also demonstrated that the proposed layout approach gives better layout design in comparison with the existing approaches.

A bi-objective Optimization Model for a Dynamic Cell Formation Integrated with Machine and Cell Layouts in a Fuzzy Environment

“…Due to a No Free Lunch theory, this chance for a new meta-heuristic algorithm always exists to reveal a better output in comparison with other existing algorithms [23]. In regards to this theory, this study employs two recent nature-inspired meta-heuristics including Keshtel Algorithm (KA) and Red Deer Algorithm (RDA) [56,57].…”

“…Hence, incorporating the facility layout problem in the CMS design process is of high significance. However, the layout design in a CMS has not paid much attention since most of the relevant research only investigates the CFP [20][21][22][23][24]. As stated in Alfa et al [2], facility layout and CF decisions are interrelated and tellingly addressing them simultaneously is important for the successful CMS design.…”

“…As stated in Alfa et al [2], facility layout and CF decisions are interrelated and tellingly addressing them simultaneously is important for the successful CMS design. However, each of these decisions is proven to be complex [21][22][23][24][25]. As a result, the simultaneous addressing of these decisions is a difficult issue.…”

A two-stage stochastic model for designing cellular manufacturing systems with simultaneous multiple processing routes and subcontracting

“…The main advantages expected from production using CMS include a reduction in work-in-process inventories, setup times, lead times, material handling costs, and tool requirements. Production using CMS also causes a noticeable improvement in productivity, product quality, and production control [1][2][3]. According to what has been presented by Wemmerl ov and Hyer [1], the following decisions could be taken in the design stage of CMSs:…”

“…For instance, the CF problem has been addressed in [4][5][6][7]. The layout of CMS has been discussed in [3,[8][9][10][11]. The cell scheduling problem has been considered in [12][13][14][15].…”