An improvement of a cellular manufacturing system design using simulation analysis

Cell Formation (CF) problem involves grouping the parts into part families and machines into manufacturing cells, so that parts with similar processing requirements are manufactured within the same cell. Many researches have suggested methods for CF. Few of these methods; have addressed the possible existence of exceptional elements (EE) in the solution and the effect of correspondent intercellular movement, which cause lack of segregation among the cells. This paper presents a simulation-based methodology, which takes into consideration the stochastic aspect in the cellular manufacturing (CM) system, to create better cell configurations. An initial solution is developed using any of the numerous CF procedures. The objective of the proposed method which provides performances ratings and cost-effective consist in determine how best to deal with the remaining EE. It considers and compares two strategies (1) permitting intercellular transfer and (2) exceptional machine duplication. The process is demonstrated with a numerical exampleCell Formation; Exceptional Elements; Simulation; Alternative costs; Improvement

A New Combined Framework for the Cellular Manufacturing Systems Design

Cellular Manufacturing (CM) system has been recognized as an efficient and effective way to improve productivity in a factory. In recent years, there have been continuous research efforts to study different facet of CM system. The literature does not contain much published research on CM design which includes all design aspects. In this paper we provide a framework for the complete CM system design. It combines Axiomatic Design (AD) and Experimental Design (ED) to generate several feasible and potentially profitable designs. The AD approach is used as the basis for establishing a systematic CM systems design structure. ED has been a very useful tool to design and analyze complicated industrial design problems. AD helps secure valid input-factors to the ED. An element of the proposed framework is desmontrate through a numerical example for cell formation with alternative process.Cellular manufacturing; Design methodology Axiomatic Design; Experimental Design.

A Taguchi method application for the part routing selection in Generalized Group Technology: A case Study

Cellular manufacturing (CM) is an important application of group technology (GT) that can be used to enhance both flexibility and efficiency in today’s small-to-medium lot production environment. The crucial step in the design of a CM system is the cell formation (CF) problem which involves grouping parts into families and machines into cells. The CF problem are increasingly complicated if parts are assigned with alternative routings (known as generalized Group Technology problem). In most of the previous works, the route selection problem and CF problem were formulated in a single model which is not practical for solving large-scale problems. We suggest that better solution could be obtained by formulating and solving them separately in two different problems. The aim of this case study is to apply Taguchi method for the route selection problem as an optimization technique to get back to the simple CF problem which can be solved by any of the numerous CF procedures. In addition the main effect of each part and analysis of variance (ANOVA) are introduced as a sensitivity analysis aspect that is completely ignored in previous research.Cellular Manufacturing; generalized Group Technology; route selection problem; Taguchi method; ANOVA; sensitivity analysis

Formation of machine groups and part families in cellular manufacturing systems using a correlation analysis approach

The important step in the design of a cellular manufacturing (CM) system is to identify the part families and machine groups and consequently to form manufacturing cells. The scope of this article is to formulate a multivariate approach based on a correlation analysis for solving cell formation problem. The proposed approach is carried out in three phases. In the first phase, the correlation matrix is used as similarity coefficient matrix. In the second phase, Principal Component Analysis (PCA) is applied to find the eigenvalues and eigenvectors on the correlation similarity matrix. A scatter plot analysis as a cluster analysis is applied to make simultaneously machine groups and part families while maximizing correlation between elements. In the third stage, an algorithm is improved to assign exceptional machines and exceptional parts using respectively angle measure and Euclidian distance. The proposed approach is also applied to the general Group Technology (GT) problem in which exceptional machines and part are considered. Furthermore, the proposed approach has the flexibility to consider the number of cells as a dependent or independent variable. Two numerical examples for the design of cell structures are provided in order to illustrate the three phases of proposed approach. The results of a comparative study based on multiple performance criteria show that the present approach is very effective, efficient and practical.cellular manufacturing; cell formation; correlation matrix; Principal Component Analysis; exceptional machines and parts

DEVELOPPEMENT D’UN MODÈLE D’ESTIMATION DES COÛTS D’ASSEMBLAGES SOUDÉS

Estimating the manufacturing cost is a critical task with high importance to industrial firms. The cost estimating can drive bidding strategies, management of resources, production policies and other issues crucial to the economic success of the company. Essentially, cost estimation should be quick and accurate. There are three main approaches towards cost estimation: estimation based on past experience (variant cost estimation), estimation based on explicit cost computations (analytical method) and parametric cost estimation. However, the most accurate cost estimates are made using the analytical approach. Among the many methods for cost estimating are those based on knowledge bases, features, operations, physical relationships and similarity laws. The aim of this study is to estimate different cost for the specific field of arc welding. It deals with assembly modeling welding. To do this, we have proposed a new application of feature: welding feature and preparation feature. This concept is based on the decomposition of the product in features. The proposed model presents a combination of two variants approach cost estimation based on characteristics of product and on manufacturing activity of process: • First, we developed an analytical method in order to estimate the welding time by determining the weight of the weld and this for each feature. Besides, we estimate others consumptions: gas, electrode and electrical power. • Second, we used parametric cost estimation for cost formulation due to deferent “feature cost” which compose the process of welding: Edge preparation (chamfering, bevel machining, grinding etc.), welding. This concept inquires the appropriate choice of the indicator. We have developed a database with Microsoft Access in order to estimate cost welding which use our model. This application, named SOUDABASE, helps in estimating welding time and cost. It will allow a relative novice to understand the effects of welding variables on production costs. Finally, we tested SOUDABASE application with industrial examples and we released a comparative study with DEVISOUD application proposed by CETIM, Senlis France in order to validate our model

A comprehensive literature classification of simulation optimisation methods

Simulation Optimization (SO) provides a structured approach to the system design and configuration when analytical expressions for input/output relationships are unavailable. Several excellent surveys have been written on this topic. Each survey concentrates on only few classification criteria. This paper presents a literature survey with all classification criteria on techniques for SO according to the problem of characteristics such as shape of the response surface (global as compared to local optimization), objective functions (single or multiple objectives) and parameter spaces (discrete or continuous parameters). The survey focuses specifically on the SO problem that involves single per-formance measureSimulation Optimization, classification methods, literature survey

Developement of welding cost estimation model based on welding feature concept

Estimating the manufacturing cost is a critical task with high importance to industrial firms. The cost estimating can drive bidding strategies, management of resources, production policies and other issues crucial to the economic success of the company. Essentially, cost estimation should be quick and accurate. There are three main approaches towards cost estimation: estimation based on past experience (variant cost estimation), estimation based on explicit cost computations (analytical method) and parametric cost estimation. However, the most accurate cost estimates are made using the analytical approach. Among the many methods for cost estimating are those based on knowledge bases, features, operations, physical relationships and similarity laws. The aim of this study is to estimate different cost for the specific field of arc welding. It deals with assembly modeling welding. To do this, we have proposed a new application of feature: welding feature and preparation feature. This concept is based on the decomposition of the product in features. The proposed model presents a combination of two variants approach cost estimation based on characteristics of product and on manufacturing activity of process: • First, we developed an analytical method in order to estimate the welding time by determining the weight of the weld and this for each feature. Besides, we estimate others consumptions: gas, electrode and electrical power. • Second, we used parametric cost estimation for cost formulation due to deferent “feature cost” which compose the process of welding: Edge preparation (chamfering, bevel machining, grinding etc.), welding. This concept inquires the appropriate choice of the indicator. We have developed a database with Microsoft Access in order to estimate cost welding which use our model. This application, named SOUDABASE, helps in estimating welding time and cost. It will allow a relative novice to understand the effects of welding variables on production costs. Finally, we tested SOUDABASE application with industrial examples and we released a comparative study with DEVISOUD application proposed by CETIM, Senlis France in order to validate our model.Modeling; Assembly; Welding feature; Preparation feature; Cost feature; Cost estimation

A Taguchi method application for the part routing selection in Generalized Group Technology: A case Study

Cellular manufacturing (CM) is an important application of group technology (GT) that can be used to enhance both flexibility and efficiency in today’s small-to-medium lot production environment. The crucial step in the design of a CM system is the cell formation (CF) problem which involves grouping parts into families and machines into cells. The CF problem are increasingly complicated if parts are assigned with alternative routings (known as generalized Group Technology problem). In most of the previous works, the route selection problem and CF problem were formulated in a single model which is not practical for solving large-scale problems. We suggest that better solution could be obtained by formulating and solving them separately in two different problems. The aim of this case study is to apply Taguchi method for the route selection problem as an optimization technique to get back to the simple CF problem which can be solved by any of the numerous CF procedures. In addition the main effect of each part and analysis of variance (ANOVA) are introduced as a sensitivity analysis aspect that is completely ignored in previous research

An improvement of a cellular manufacturing system design using simulation analysis

Cell Formation (CF) problem involves grouping the parts into part families and machines into manufacturing cells, so that parts with similar processing requirements are manufactured within the same cell. Many researches have suggested methods for CF. Few of these methods; have addressed the possible existence of exceptional elements (EE) in the solution and the effect of correspondent intercellular movement, which cause lack of segregation among the cells. This paper presents a simulation-based methodology, which takes into consideration the stochastic aspect in the cellular manufacturing (CM) system, to create better cell configurations. An initial solution is developed using any of the numerous CF procedures. The objective of the proposed method which provides performances ratings and cost-effective consist in determine how best to deal with the remaining EE. It considers and compares two strategies (1) permitting intercellular transfer and (2) exceptional machine duplication. The process is demonstrated with a numerical exampl