The facets of group technology and their impacts on implementation—A state-of-the-art survey

The recent use of the Group Technology concept of grouping parts into ‘families’ has received much notice due to the integration of this technique with the varied technologies of computer integrated manufacturing. This is but one of the facets of Group Technology, which is essentially a set of techniques and operating policies designed to improve the operational efficiency of manufacturing. With the exception of the parts grouping concept, the many facets of Group Technology have been largely neglected. This paper presents a survey of the literature on the concepts of Group Technology, attempts to categorize these topics in a natural manner, and link the processes, technology and experiences together. This paper reviews the problems addressed and the optimal and heuristic solution methodologies suggested in the literature. The conclusion indicate various areas and topics for future research/implementation activities.     

A methodology for the design of manufacturing systems using group technology

The primary objectives in implementing computer integrated manufacturing systems (CIMS) are to improve quality, enhance flexibility, and increase productivity. One of the approaches used to achieve these objectives is to organize and group the production machines into manufacturing cells using group technology concepts. Cellular manufacturing allows small batch production to gain economic advantages similar to mass production while maintaining the flexibility of job shop production. This paper presents a methodology which uses design and manufacturing attributes to form manufacturing cells in a computer integrated manufacturing setting. The methodology is implemented in two phases. In phase I, parts are grouped into part families based on their design and manufacturing attributes. In phase II of the methodology, the machines are grouped into manufacturing cells based on relevant operational costs, and the various cells are assigned part families using an optimization technique. The optimization technique employs integer programming to minimize the total operational costs.     

基于同质设备多台配置的独立生产单元构建决策

单元化生产作为一种较好实现生产柔性与生产效率融合的先进生产方式,在变种变量需求环境下它已被大量生产企业特别是装配式生产企业所采用。生产单元构建问题是单元化生产系统设计的关键问题和首要问题,也是单元化生产研究领域的一个热点。本文研究设备易复制情形下,通过配置多台同质设备来实现生产单元间无物料移动,并保证生产单元间工作量均衡的独立生产单元构建问题。本文在综合考虑换装时间、加工顺序、设备生产能力、产品需求量等多个实际生产要素的基础上,建立了以平均总流程时间和各生产单元总流程时间与平均总流程时间偏差最小为目标的数学模型,并开发了一个启发式算法来求解数学模型,最后通过数值算例验证了模型和算法的有效性。     

Simulation-based performance assessment of master planning approaches in semiconductor manufacturing

Semiconductor manufacturing is confronted with a large number of products whose mix is changing over time, heterogeneous fabrication processes, re-entrant flows of material, and different sources of environmental and system uncertainty. In this context, the mid-term production planning approach, i.e., master planning, typically does not capture the entire complexity of the shop-floor. It deals with an aggregated representation of the production system. There is a need for evaluating the planning algorithm in use while taking the execution level into account. Therefore, we introduce in this paper a simulation-based framework that allows for modeling the behavior of the market demand and the production system. An appropriate performance assessment methodology is proposed. The performance of two heuristic approaches for master planning in semiconductor manufacturing, a genetic algorithm and a rule-based assignment procedure, is evaluated within a rolling horizon setting while considering demand and execution uncertainty. A reduced discrete-event simulation model is used to mimic a one-stage network of wafer fabrication facilities. The results of simulation experiments are discussed.     

The Ordered Cutting Stock Problem

The one‐dimensional cutting stock problem (CSP) is a classic combinatorial optimization problem in which a number of parts of various lengths must be cut from an inventory of standard‐size material. The classic CSP ensures that the total demand for a given part size is met but ignores the fact that parts produced by a given cutting pattern may be destined for different jobs. As a result, applying the classic CSP in a dynamic production environment may result in many jobs being open (or partially complete) at any point in time—requiring significant material handling or sorting operations. This paper identifies and discusses a new type of one‐dimensional CSP, called the ordered CSP, which explicitly restricts to one the number of jobs in a production process that can be open, or in process, at any given point in time. Given the growing emphasis on mass customization in the manufacturing industry, this restriction can help lead to a reduction in both in‐process inventory levels and material handling activities. A formal mathematical formulation is provided for the new CSP model, and its applicability is discussed with respect to a production problem in the custom door and window manufacturing industry. A genetic algorithm (GA) solution approach is then presented, which incorporates a customized heuristic for reducing scrap levels. Several different production scenarios are considered, and computational results are provided that illustrate the ability of the GA‐based approach to significantly decrease the amount of scrap generated in the production process.     

MODELS FOR OPTIMAL LEAD TIME REDUCTION

Most inventory and production planning models in the academic literature treat lead times either as constants or random variables with known distributions outside of management control. However, a number of recent articles in the popular press have argued that reducing lead times is a dominant issue in manufacturing strategy. The benefits of reducing customer lead times that are frequently cited include increased customer demand, improved quality, reduced unit cost, lower carrying cost, shorter forecast horizon, less safety stock inventory, and better market position. Although the costs of reducing lead times in the long term may be relatively insignificant compared with the benefits, in the short term these costs can have a significant impact on the profitability of a firm. This article develops a conceptual framework within which the costs and benefits of lead time reduction can be compared. Mathematical models for optimal lead time reduction are developed within this framework. The solutions to these models provide methods for calculating optimal lead times, which can be applied in practice. Sensitivity analysis of the optimal solutions provides insight into the structure of these solutions.     

Implementation of just-in-time methodology in a small company

This paper describes the implementation of JIT in a small manufacturing company and the benefits that resulted for the company's operations. Preliminary analysis identified various problems in the existing manufacturing operations. The pre-implementation and post-implementation conditions of the company arc detailed. The achievements of the JIT implementation included a reduction in material traversing, reduced lead limes and inventories leading to an overall reduction in the cost of manufacturing. A smooth flow of material from the raw material stage to the finished product stage was established. Three separate product lines were combined into a flexible manufacturing assembly line. With the adoption of a holistic approach to JIT implementation, it was found that even a small company can make significant strides towards world class manufacturing status. The experience gained by the company can encourage and benefit other small companies to embrace the JIT approach.     

An evaluation of product commonality and group technology production methods in a pre-defined multiple-machine scenario

Group technology has been used successfully for a number of years as a setup reduction tool. It is especially valuable in low-volume high-mix manufacturing environments where products and machines may be partitioned into product families and machine cells. The partitioning of machines or processes into cells may be limited by practical constraints, and the partitioning of products is complicated as the number of products and processes increases. In this paper, the authors examine the behaviour of various grouping strategies lauded as being appropriate in situations where machine partitioning and product routeing are determined by technological constraints. Of specific experimental concern in this paper is the effect of the mean and variance of component part commonality between products on system performance under various grouping strategies in a multiple-machine environment.     

A multicriteria model for supporting setup reduction investment decisions

One critical manufacturing challenge of the 1990s is for firms to effectively apply new operations management techniques while embracing wider philosophies such as total quality management (TQM) and computer integrated manufacturing (CIM), etc. Setup cost and/or time reduction is one such technique capable of producing many benefits for manufacturing firms, including reduced inventory, better equipment utilization, and improved quality. It is thereby viewed as an important component of just-in-time (JIT) manufacturing practice. Existing problems with the setup reduction decision include the many factors that must be considered, as well of an absence of validated and usable models for estimating potential benefits from setup reduction investment made in different contexts. This paper discusses the attainment of gains from setup reduction mainly by improving existing equipment and work practices rather than purchasing new equipment or technology. The model proposed in this paper is based on the application of the analytic hierarchical process (AHP) on seven weighted factors to obtain a preliminary indication as to whether investment in setup reduction is desirable in a given manufacturing context, and the expected benefits of such investment. A flexible scaling system, thus obtained, allows the model to handle a wide range of managerial predispositions to setup reduction.     

A Virtual Cellular Manufacturing Approach to Batch Production*

In this paper, Virtual Cellular Manufacturing (VCM), an alternative approach to implementing cellular manufacturing, is investigated. VCM combines the setup efficiency typically obtained by Group Technology (GT) cellular manufacturing (CM) systems with the routing flexibility of a job shop. Unlike traditional CM systems in which the shop is physically designed as a series of cells, family-based scheduling criteria are used to form logical cells within a shop using a process layout. The result is the formation of temporary, virtual cells as opposed to the more traditional, permanent, physical cells present in GT systems. Virtual cells allow the shop to be more responsive to changes in demand and workload patterns. Production using VCM is compared to production using traditional cellular and job shop approaches. Results indicate that VCM yields significantly better flow time and due date performance over a wide range of common operating conditions, as well as being more robust to demand variability.     

考虑分时电价的多目标批调度问题蚁群算法求解

对同时优化电力成本和制造跨度的多目标批处理机调度问题进行了研究,设计了两种多目标蚁群算法,基于工件序的多目标蚁群算法(J-PACO,Job-based Pareto Ant Colony Optimization)和基于成批的多目标蚁群算法(B-PACO,Batch-based Pareto Ant Colony Optimization)对问题进行求解分析。由于分时电价中电价是时间的函数,因而在传统批调度进行批排序的基础上,需要进一步确定批加工时间点以测定电力成本。提出的两种蚁群算法分别将工件和批与时间线相结合进行调度对此类问题进行求解。通过仿真实验将两种算法对问题的求解进行了比较,仿真实验表明B-PACO算法通过结合FFLPT(First Fit Longest Processing Time)启发式算法先将工件成批再生成最终方案,提高了算法搜索效率,并且在衡量算法搜索非支配解数量的Q指标和衡量非支配集与Pareto边界接近程度的HV指标上,均优于J-PACO算法。     

A note on the within-cell layout problem based on operation sequences

The existing studies in the literature usually ignore the within-cell layout problem while forming part families and manufacturing cells. A new approach is proposed to solve the part-family and machine-cell formation problem and to determine the spatial arrangement of machines in each cell simultaneously. Furthermore, a dissimilarity measure between parts based on operation sequences is presented since the operation sequences not only specify the type of machine tools needed but also impact the flow of material. As a result, we can both minimize the material handling cost and streamline the material flow in each cell.     

Group technology and growth at Shalibane

Abstract. The Shalibane Company of Camberley are tube manipulators and sheet metal workers, making parts mainly for the car industry. In 1991 they introduced Group Technology (GT). In eighteen months they reduced stocks by 60% (still falling); increased sales and output by 33%; increased the rate of return on investment by 24%; and increased the number of their employees by 12%. The cost of introducing the change was covered more than 3 times by the reduction in the stock investment. GT is shown to be a method which promotes growth and increases productivity, profitability and employment.     

A simulated annealing algorithm for designing cellular manufacturing systems with productivity consideration

In this paper, we propose a productivity model for solving the machine-part grouping problem in cellular manufacturing (CM) systems. First, a non-linear 0-1 integer programming model is developed to identify machine groups and part families simultaneously. This model aims to maximize the system productivity defined as the ratio of total output to the total material handling cost. Second, an efficient simulated annealing (SA) algorithm is developed to solve large-scale problems. This algorithm provides several advantages over the existing algorithms. It forms part families and machine cells simultaneously. It also considers production volume, sales price, and maximum number of machines in each cell and total material handling cost. The proposed SA also has the ability to determine the optimum number of manufacturing cells. The performance of the developed models is tested on eight problems of different size and complexity selected from the literature. The results show the superiority of the SA algorithm over the mathematical programming model in both productivity and computational time.     

The Value of Information for Managing Retail Inventory Remotely

An important difference between both manufacturing and wholesaling vs. retail is the information available concerning inventory. Typically, far less information characterizes retail. Here, an extreme environment of information shortfall is examined. The environment is technically termed “unattended points of sale,” but colloquially called vending machines. Once inventory is loaded into a machine, information on demand and inventory level is not observed until the scheduled reloading date. Technological advances and business process changes have drawn attention to the value of information (VOI) in retail inventory in many venues. Moreover, technology is now available that allows unattended points of sale to report inventory information. Capturing the value of this information requires changes in current business practice. We demonstrate the value of capturing information analytically in an environment with restrictive demand assumptions. Experiments in an environment with realistic demand assumptions and parameter values show that the VOI depends greatly on operating characteristics and can range from negligible effects to increasing profitability 30% or more in actual practice.     

Processing in a multi-machine batch manufacturing system with sequence dependent cost

Many workcells in batch manufacturing systems are populated with multiple, nonidentical machines that perform similar tasks. Because of the size of a batch when a job arrives, it may be uneconomical to set up two or more machines to process the same job simultaneously. An economic decision has to be made as regards which machine in the cell to assign the job. Likewise, many multi-operation jobs can be processed using one of several feasible operation sequences that may lead to different total manufacturing costs. The cost differences are the result of several factors, among which are processing time and cost dependencies between operations, fixturing requirements, and material handling requirements. When the workcell machine selection decision is considered along with the operation sequencing decision, determination of the best machine in a cell and the best operation sequence for the batch is a non-trivial task. In this paper, we address the problem of selecting the best machine within a cell and the best operation sequence for a batch when operation cost is machine and sequence dependent. The problem is modeled mathematically and solved using a heuristic algorithm. The performance of the algorithm is compared with that of an exact solution procedure.     

An Optimal Model for Cell Formation Decisions

This study develops an approach to cell formation decisions for cellular manufacturing layouts in group technology settings. An optimal 0–1 integer programming model is used to provide an analysis for determining which machines and parts should be assigned to cells in cellular manufacturing layouts. This approach minimizes the cost of manufacturing exceptional parts outside the cellular system, subject to machine capacity constraints. Part–machine matrices are partitioned into disconnected cells and use far fewer 0–1 variables than earlier approaches. Formulation of the model is described with a numerical example and computer solutions to realistic problems are obtained. The characteristics of computer run times, model performance, and applications of the model are discussed.     

A multiobjective model and evolutionary algorithms for robust time and space assembly line balancing under uncertain demand

Changes in demand when manufacturing different products require an optimization model that includes robustness in its definition and methods to deal with it. In this work we propose the r-TSALBP, a multiobjective model for assembly line balancing to search for the most robust line configurations when demand changes. The robust model definition considers a set of demand scenarios and presents temporal and spatial overloads of the stations in the assembly line of the products to be assembled. We present two multiobjective evolutionary algorithms to deal with one of the r-TSALBP variants. The first algorithm uses an additional objective to evaluate the robustness of the solutions. The second algorithm employs a novel adaptive method to evolve separate populations of robust and non-robust solutions during the search. Results show the improvements of using robustness information during the search and the outstanding behavior of the adaptive evolutionary algorithm for solving the problem. Finally, we analyze the managerial impacts of considering the r-TSALBP model for the different organization departments by exploiting the values of the robustness metrics.     

Integration of CAD/CAM and production control in sheet metal manufacturing — an application area of operations research

Abstract

This paper describes a process planning system for sheet metal parts. This system has capabilities to deliver process planning data just in time. The change of tools, processes and even machines for manufacturing of the parts is possible at the shop door after design has been finished.

The sequence of the production planning steps carried out can be changed. In this way the system can be adapted to the requirements of different sheet metal manufacturing companies.

More detailed information is given about the methods used for nesting of the workpieces on the sheets to be produced.     

On the Benefits of Risk Pooling in Inventory Management

We analyze the benefits of inventory pooling in a multi‐location newsvendor framework. Using a number of common demand distributions, as well as the distribution‐free approximation, we compare the centralized (pooled) system with the decentralized (non‐pooled) system. We investigate the sensitivity of the absolute and relative reduction in costs to the variability of demand and to the number of locations (facilities) being pooled. We show that for the distributions considered, the absolute benefit of risk pooling increases with variability, and the relative benefit stays fairly constant, as long as the coefficient of variation of demand stays in the low range. However, under high‐variability conditions, both measures decrease to zero as the demand variability is increased. We show, through analytical results and computational experiments, that these effects are due to the different operating regimes exhibited by the system under different levels of variability: as the variability is increased, the system switches from the normal operation to the effective and then complete shutdown regimes; the decrease in the benefits of risk pooling is associated with the two latter stages. The centralization allows the system to remain in the normal operation regime under higher levels of variability compared to the decentralized system.