The evolution of cell formation problem methodologies based on recent studies (1997-2008): review and directions for future research

This paper presents a literature review of the cell formation (CF) problem concentrating on formulations proposed in the last decade. It refers to a number of solution approaches that have been employed for CF such as mathematical programming, heuristic and metaheuristic methodologies and artificial intelligence strategies. A comparison and evaluation of all methodologies is attempted and some shortcomings are highlighted. Finally, suggestions for future research are proposed useful for CF researchers

Formación de celdas de manufacturas dinámicas para la toma de decisiones en el diseño de instalaciones industriales: una revisión

This paper presents a literature review with the purpose of characterizing the Dynamic Manufacturing Cell Formation Problem by means of the identification of optimization criteria, the most relevant restrictions needed for consideration and the most frequently used solution methods. Hence, an adaptation of the PRISMA statement was conducted for systematic reviews along with Snowball Methodology to select the studies to be analyzed. The document search is carried out in the Web of Science and Scopus databases, considering a time frame between 2007 and 2019. As a general result, it was found that cost minimization is the most frequently used optimization criterion and the typically considered constraints are associated with part machine operation sequence, machine breakdowns, and lot size. On the other hand, considering the highly combinatorial nature of the optimization problems reviewed, it was found that metaheuristics are the most used solution method, and genetic algorithms as well as simulated annealing are the most frequently implemented. Finally, three research trends are determined: incorporation of two or more optimization criteria in a mathematical formulation, development and implementation of hybrid metaheuristic algorithms, and comparison of performance of the existing solution methods based on reference problems or real industrial applications.Este artículo presenta una revisión de literatura con el fin de caracterizar el Problema de Formación de Celdas de Manufactura Dinámicas, realizando la identificación de los criterios de optimización, las principales restricciones consideradas y los métodos de solución más usados. Para ello, se condujo una adaptación de la declaración PRISMA para revisiones sistemáticas, en conjunto con una metodología bola de nieve para la selección de los estudios a analizar; la búsqueda de documentos se realiza en las bases de datos Web of Science y Scopus, considerando una ventana de tiempo entre 2007 y 2019. Como resultados generales, se encuentra que la minimización de costos es el criterio de optimización utilizado con mayor frecuencia y que las restricciones usualmente consideradas están asociadas a la secuencia de operaciones, averías de máquinas, y variación del tamaño de lote de procesamiento. De otra parte, considerando la naturaleza altamente combinatoria de los problemas de optimización revisados, se encuentra que los métodos de solución metaheurísticos utilizados en mayor medida son algoritmos genéticos, y recocido simulado. Finalmente, se determinan tres tendencias de investigación primero, la incorporación de dos o más criterios de optimización en una formulación matemática; segundo, el desarrollo e implementación de algoritmos metaheurísticos híbridos y; tercero, la evaluación de los métodos de solución existentes a partir de problemas de referencia o aplicaciones industriales reales

Cell Production System Design: A Literature Review

Purpose In a cell production system, a number of machines that differ in function are housed in the same cell. The task of these cells is to complete operations on similar parts that are in the same group. Determining the family of machine parts and cells is one of the major design problems of production cells. Cell production system design methods include clustering, graph theory, artificial intelligence, meta-heuristic, simulation, mathematical programming. This article discusses the operation of methods and research in the field of cell production system design. Methodology: To examine these methods, from 187 articles published in this field by authoritative scientific sources, based on the year of publication and the number of restrictions considered and close to reality, which are searched using the keywords of these restrictions and among them articles Various aspects of production and design problems, such as considering machine costs and cell size and process routing, have been selected simultaneously. Findings: Finally, the distribution diagram of the use of these methods and the limitations considered by their researchers, shows the use and efficiency of each of these methods. By examining them, more efficient and efficient design fields of this type of production system can be identified. Originality/Value: In this article, the literature on cell production system from 1972 to 2021 has been reviewed

Uso de métodos heurísticos e branch-and-bound para otimização do layout fabril da linha de montagem de um componente automotivo na região de Curitiba

Nowadays, the manufacturing enterprises are constantly looking for costs reduction, driven by rivalry and competition, which are strong globalization characteristics. In the Toyota Production System (OHNO, 1988), are highlighted the seven wastes which can exist in a manufacturing process and that, consequently, generate costs to the product without, however, adding value to it. Some commonly found wastes are the work-in-process (WIP), raw material or finished products flow wastes. The layout study aims to optimize the layout of facilities inside a process to minimize, among others, the materials flow. This study aims to present a real case of a huge auto parts manufacturer enterprise located in Curitiba, PR, which spends millions a year on layout changes. The object of study is the assembly line of a specifical component that this company manufactures. Using Heuristic methods, it proposes an approach for the layout optimizing of this assembly line. This approach was divided in two stages: in the first one, the cell formation problem (in order to improve the computational time, as well as the solution quality) was solved in order to associate machines to parts. In the second stage, the layout optimizing problem is solved, considering the combination of machines to parts (made in first stage). In both stages the hybrid meta-heuristics approach (tabu search), as well as the Exact method so called Branch-and-Bound (this on first stage), were tested to solve this problem. The results found on layout of facilities were quite promising.As empresas de manufatura, nos dias atuais, estão incessantemente em busca de redução de custos, motivadas pela concorrência e competição, que são características fortes da globalização. No Sistema Toyota de Produção (OHNO, 1988) é ressaltada a questão dos sete desperdícios que podem existir em um processo e que, consequentemente, geram custos no produto sem, contudo agregar valor ao mesmo. Um dos desperdícios mais comumente encontrados são os do fluxo do produto semiacabado (WIP), matéria-prima ou produto acabado. O estudo de Layout visa otimizar a disposição dos recursos dentro de um processo de modo a minimizar, entre outros, o fluxo de materiais. O presente estudo visa apresentar um caso real de uma grande empresa de autopeças na região de Curitiba, PR, que gasta milhões por ano em mudanças de Layout. O objeto de estudo é a linha de montagem de um determinado componente que esta empresa fabrica. Através do uso de Métodos Heurísticos propõe-se uma abordagem para a otimização do Layout desta linha de montagem. Esta abordagem foi dividida em duas etapas. Na primeira etapa, foi resolvido o problema de formação de células (visando melhorar os tempos computacionais, bem como a qualidade da solução), visando associar as máquinas disponíveis às peças a serem fabricadas. Na segunda etapa, resolve-se o problema de otimização do layout, considerando as associações de máquinas às peças feitas na primeira etapa. Nas duas etapas testou-se o uso de uma abordagem meta-heurística (busca tabu) híbrida, bem como o método exato denominado Branch-and-Bound (este na primeira etapa), para resolver o problema. Os resultados encontrados no arranjo físico das máquinas mostraram-se bastante promissores

The development of methods for the design and evolution of reconfigurable cellular manufacturing systems.

Doctor of Philosophy in Engineering (Mechanical Engineering)The concept of reconfigurable manufacturing is presently being researched due to the need for production systems that are able to economically respond to changes in markets and the rapid introduction of new products. Cellular Manufacturing Systems (CMS) are a central concept in just-in-time and lean manufacturing. Although CMS are able to provide a strategic operating advantage, machine cell clusters do not remain optimal over an extended period of time. The concept of a Dynamic CMS (DCMS) has received attention in recent years; a DCMS is a system where the layout of machines change in order to improve the responsiveness of CMS to changing production requirements. A deficiency in existing DCMS methods is that reconfiguration plans are generated without the consideration of an initial design of the factory floor space for future change. This research distinguishes Reconfigurable CMS (RCMS) from DCMS, as a system that is designed at the outset for changes to system layout and cell configurations. The concept of a Factory Configuration Template (FCT) is proposed in this research; the FCT is a design of the factory floor space to ensure the feasible implementation of reconfiguration plans generated by mathematical models. A nine step method for FCT design is presented that uses a Simultaneous Fuzzy Clustering Heuristic to develop manufacturing cells and part families. A Tabu Search algorithm was develop to generate the optimal arrangement of machine sites in cells. Three multi-period machine assignment models were developed that determine reconfiguration plans based on changing product demand and the introduction of new products. The models that were developed included two integer linear programs that determine the distribution of machine resources among cells over multiple periods. A quadratic zero-one programming model was developed that distributes machines among available sites in cells to promote unidirectional part flow. The results show that RCMS is able to provide a more economical solution than traditional CMS with the added advantage of improved part flow in the system