DESIGN OF CELLULAR MANUFACTURING SYSTEM UNDER DYNAMIC ENVIRONMENT FOR AN AUTO-COMPONENT MANUFACTURING INDUSTRY
Keywords:
Cellular Manufacturing System, Dynamic Production Requirements, Reconfiguration, Routing Flexibility , Case StudyAbstract
Shorter product life-cycles, unpredictable demand, and customized products have forced manufacturing firms to operate more efficiently and effectively in order to adapt to changing requirements. Traditional manufacturing systems, such as job shops and flow lines, cannot handle such environments. Cellular manufacturing system (CMS), which incorporates the flexibility of job shops and the high production rate of flow lines, has been seen as a promising alternative for such cases. The classical CMS approach is under a consideration that the products mix and demand do not change over the planning horizon i.e., the production requirement is assumed to be static in nature. This paper is aimed to develop a model and a solution approach for designing cellular manufacturing systems that addresses these shortcomings by assuming dynamic production requirements in which a planning horizon can be divided into smaller periods where each period has different product mix and demand requirements. A mathematical model and an optimal solution procedure is developed simulating the exact situation of dynamic environment with routing flexibility considering all the parameters and constraints. A case study was conducted in auto-components manufacturing industry which is a batch production industry located in Ambattur Industrial Estate, Chennai. In this paper, a solution methodology of best possible cell formation using LINGO 11.0 is presented and a critical analysis is made for converting functional layout into CMS incorporating realistic constraints and integrated approach.
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