Reconfigurability in cellular manufacturing systems: a design model and multi-scenario analysis
- 66 Downloads
Within cellular manufacturing systems (CMSs), families of parts are assigned to manufacturing cells, composed by homogeneous sets of machines. In conventional CMSs, each cell is devoted to the production of a specific part family, reducing material handling and work-in-process. Despite their flexibility, such systems still suffer from coping with the present market challenges asking for dynamic part mix and the need of agility in manufacturing. To meet these challenges, the recent literature explores the idea of including elements of the emerging reconfigurable manufacturing paradigm in the design and management of CMSs, leading to the cellular reconfigurable manufacturing system (CRMS) concept. The aim of this paper is to propose an original linear programming optimization model for the design of CRMSs with alternative part routing and multiple time periods. The production environment consists of multiple cells equipped with reconfigurable machine tools (RMTs) made of basic and auxiliary custom modules. By changing the auxiliary modules, different operations become available on the same RMT. The proposed approach determines the part routing mix and the auxiliary module allocation best balancing the part flows among RMTs and the effort to install the modules on the machines. The approach discussion is supported by a literature case study, while a multi-scenario analysis is performed to assess the impact of different CMS configurations on the system performances, varying both the number of cells and the RMT assignment to each of them. A benchmarking concludes the paper comparing the proposed CRMS against a conventional CMS configuration. The analysis shows relevant benefits in terms of reduction of the intercellular travel time (− 58.6%) getting a global time saving of about 53.3%. Results prove that reconfigurability is an opportunity for industries to face the dynamics of global markets.
KeywordsCellular manufacturing Reconfigurable manufacturing systems Reconfigurability Modularity Optimization
Compliance with ethical standards
Conflict of interest
The authors declare that they have no conflict of interest.
- 7.Lolli F, Gamberini R, Gamberi M, Bortolini M (2018) The training of suppliers: a linear model for optimising the allocation of available hours. Int J Ind Syst Eng 28(2):135–151Google Scholar
- 8.Manzini R, Accorsi R, Bortolini M (2013) Similarity-based cluster analysis for the cell formation problem. In Industrial Engineering: Concepts, Methodologies, Tools, and Applications, IGI Global, pp 499-521Google Scholar
- 21.Benderbal HH, Benyoucef L (2019) Machine layout design problem under product family evolution in reconfigurable manufacturing environment: a two-phase-based AMOSA approach. Int J Adv Manuf Technol:1–15Google Scholar
- 22.Xing B, Nelwamondo FV, Gao W, Marwala T (2009) Application of artificial intelligence (AI) methods for designing and analysis of reconfigurable cellular manufacturing systems (RCMS). Proceedings of the 2nd International Conference on Adaptive Science & Technology, pp 402-409Google Scholar
- 25.Durmusoglu MB, Cevikcan E, Satoglu SI (2018) The progress of assembly cell design from a conventional assembly system to a walking worker assembly cell. In: Süer GA, Gen M (eds) Cellular manufacturing systems: recent developments, analysis and case studies. Nova Science Publishers, Inc., New York, pp 327–343 ISBN: 978-153612880-2Google Scholar
- 27.Ateme-Nguema BH, Dao TM (2007) Optimization of cellular manufacturing systems design using the hybrid approach based on the ant colony and tabu search techniques. Proceedings of the IEEE International Conference on Industrial Engineering and Engineering Management, pp 668-673Google Scholar
- 30.Yilmaz OF, Cevikcan E, Durmusoglu MB (2016) Scheduling batches in multi hybrid cell manufacturing system considering worker resources: a case study from pipeline industry. Adv Prod Eng Manag 11(3):192–206Google Scholar
- 32.Pattanaik LN, Kumar V (2010) Multiple level of reconfiguration for robust cells formed using modular machines. Int J Ind Syst Eng 5:424–441Google Scholar
- 33.Bai JJ, Gong YG, Wang NS, Tang DB (2009) Methodology of virtual manufacturing cell formation in reconfigurable manufacturing system for make-to-order manufacturing. Comput Integr Manuf Syst 2:016Google Scholar