Novel approach to multi-channel manufacturing system design

Abstract

Volatile market conditions have made classical production organizations obsolete in the 1990s. Therefore, new means such as holonic, fractal and multi-channel production systems are investigated to enhance manufacturers' dynamic response ability and competitiveness. Amongst these, newly suggested multi-channel manufacturing (MCM) systems compromise compatibility and specialization to produce a certain range of products. This study proposes a new approach based on genetic algorithms to devise such production channels. Feasible solutions corresponding to machine sequences for channels are coded as chromosome structures. Applying genetic operations to these chromosomes created improved arrangements regarding a problem given in the literature. Furthermore, an effective and realistic solution for a real life problem was found by making use of the multi-objective fitness function developed.

Optimization of Genetic Algorithm Parameters for Multi-channel Manufacturing Systems by Taguchi Method

“…In order to investigate how GAs behave for different channel formation problems, two types of problems were tested: 7-machine 6-part problem [7M_6P] with three channels introduced by [5] and 24-machine 50-part problem [24M_50P] with four channels introduced by [7]. Based on the preliminary tests, three design factors were identified as potentially important for performance of GAs developed for [7M_6P] problem: (1) population size, (2) crossover rate, and (3) mutation rate.…”

“…Optimum design factors' levels for [7M_6P] are then used to solve [24M_50P]. The results obtained from the Taguchi method is compared with the solution of [7]. The investment cost is decreased from $484,363 to $278,474.…”

“…An initial population of strings up to the specified population size is generated at random. The objective function of the developed model by [7] is adopted as the fitness function of the proposed GA. A modified roulette wheel method where individuals are selected by randomized fitness value is applied. A two-point crossover operator is used and a mutation threshold is applied to decide the mutation time.…”

Cellular Manufacturing Systems: Organization, Trends And Innovative Methods

“…As an extreme case, some versions of fractal layouts consist of identical cells only. (2001) and Ozcelik & Islier (2003) also considered the capacities and flows in MCM design. These systems are quite flexible and adaptive, since a part likely follow a different channel if a certain channel is blocked in real time.…”

“…Montreuil et al (1999) introduced the fractal concept by dividing a plant into several quasi-identical microfactories where each fractal has the ability to produce a wide variety of parts. Multi-channel manufacturing (MCM) systems, proposed by Meller could be considered as a type of fractal entity (Ozcelik & Islier, 2003). Saad & Lassila (2004) indicated the need for a trade-off between machine quantities and material traveling distance in fractal layout design.…”