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    Integrated ManufacturingSystems9/ 6 [1998] 377382

    MCB University Press[ISSN 0957-6061]

    Redesigning jobshops to cellular manufacturingsystems

    Godfrey C. OnwuboluNational University of Science and Technology, Bulawayo, Zimbabwe

    Grouping parts into familieswhich can be produced by a

    cluster of machine cells is thecornerstone of cellular manu-facturing, which in turn is the

    building block for flexiblemanufacturing systems.

    Cellular manufacturing is agroup technology (GT) con-cept that has recently

    attracted the attention ofmanufacturing firms operat-ing in a jobshop environment

    to consider redesigning theirmanufacturing systems so asto take advantage of

    increased throughput, andreductions in work-in-

    progress, set-up time, andlead times; leading to product

    quality and customer satis-faction. Presents a similarityorder clustering technique forthe machine cell formation

    problem. The procedure iscompared with many existingprocedures using eight well-

    known problems from theliterature. The results show

    that the proposed procedure,which is attractive due to itssimplicity, compares well with

    existing procedures andshould be useful to practition-ers and researchers.

    Introduction

    Many manufacturing firms which hi therto

    satisfied their customers while operating

    jobshop production systems have recently

    had to rethink because of the superi ori ty of

    group technology (GT) philosophy of cellularmanufacturing. Cellular manufacturing

    systems (CMS) house a large variety and

    combinations of processes and shorten manu-

    facturing lead times, reduce work-in-progress

    (WIP), lower set-up times and operations

    costs, improve quali ty, increase workers job

    satisfaction and subsequent customer satis-

    faction (Wemmerlov and Hyer, 1989). Manu-

    facturing firms which embrace modern man-

    ufacturing improvement philosophies such

    as just-in-time (J IT), total quali ty manage-

    ment (TQM), business process re-engineering

    (BPR) and time-based competition (TBC) use

    the principles of CMS i n their manufacturingsystem restructur ing efforts so as to meet

    world-class manufacturing status

    (Wemmerlov and J ohnson, 1997).

    Solving flexible manufacturing systems

    (FM S) optimal production planning and

    scheduling problems through size reduction

    require grouping of parts into part families at

    the aggregate planning level (Bitran and Hax,

    1981).

    Planning and scheduli ng FMS at the disag-

    gregate level involves machines, parts and

    additional components such as tools, fixtures,

    grippers and material handling components.The costs of these components are usually

    high and they may be in l imited quantities.

    Figure 1 shows the decomposition of FMS

    planning situation at disaggregation level,

    with all the parts to be manufactured and the

    associated components being decomposed

    into disjoint part and component famil ies.

    This results in each of the individual part

    and component famil ies being easier to man-

    age. Individual part families are manufac-

    tured by machine groups which utili se associ-

    ated components such as the tools, fixtures,

    grippers and material handling components

    already mentioned.The grouping problem in GT involves diag-

    onalisation of a given machine-part incidence

    matrix into a cluster of machines which

    produce a cluster of parts. In FMS, the

    corresponding cluster of machines is referred

    to as a flexible manufacturing cell (FMC),

    while at the lower level i n the classical GT

    physical cells, the cluster of machines is ordi-

    nari ly referred to as a manufacturing cell .

    Since a manufacturing cell is the building

    block of FMC, the discussion in the remain-ing sections of this paper concentrate on

    machine and part families grouping without

    loss of generality.

    Machine cell f ormation t echniques

    Various approaches to cell formation have

    since been reported and may fall under one of

    the six major classifications: array-based

    clustering, similarity coefficient, mathemati-

    cal programming, graph and network, heuris-

    tic and combinatorial optimisation.

    There are two types of array-based cluster-ing techniques; rank order clusteri ng (ROC)

    and bond energy analysis (BEA). In ROC, a

    positional based value is assigned to each 1

    in the machine-part incidence matrix and the

    values of all the 1s in each row and each

    column are summed, the rows and columns

    being rearranged in decreasing order based

    on the values from top to bottom, and from

    left to right respectively (K ing, 1980). This

    process is continued until an invariant

    matrix is obtained resulting in a clusteri ng of

    machines and parts along the diagonal.

    Extensions to ROC to include cost data (Askinand Subramanian, 1987) and prevention of

    positional based value getting extremely

    large for large number of machines and parts

    (King and Narkor nchai, 1982) have been

    reported. Progressive slicing of identified

    group after one iteration of row ranking and

    one iteration of column ranking

    (Chandrasekharan and Rajagopalan, 1986a)

    have led to drastic improvement in ROC

    results. The bond energy which is defined as

    the product of the values of the adjoining row

    and column elements in the machine-part

    incidence matrix to determine the degree ofclustering has been successfully

    implemented, with an optimal solution being

    one which maximi ses the bond energy

    (McCormick et a l., 1972).

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    The first work to use similarity measures to

    group machines and parts into cells

    (McAuley, 1972) utili ses a similarity matrix

    which contains all pairwi se similarity coeffi-

    cients between each machine. The similarity

    matrix obtained is then used by the single

    linkage clusteri ng algori thm (SLCA) to formthe machine groups. These methods have

    been adopted by other researchers (de Witte,

    1980; Seifoddini and Wolfe, 1986; Tam, 1990;

    Waghodekar and Sahu, 1984). The clustering

    algori thms based on the similarity coefficient

    fall into two classifications: hierarchical and

    non-hierarchical. Both the single linkage

    clustering algorithm and the average cluster-

    ing algori thm are hierarchical clusteri ng

    algori thms. The only known non-hierarchical

    clustering reported so far include

    MacQueens k-means method (MacQueen,

    1967) which requires the number of clusters

    to be specified in advance, the ideal-seed algo-

    rithm (Chandrasekharan and Rajagopalan,

    1986b) and its improved version ZODIAC

    (Chandrasekharan and Rajagopalan, 1987).

    Thep-median model based on an integer

    programming formulation, which seeks to

    maximise the sum of similari ty coefficients

    for a fixed number of groups with the con-

    straints that a part wi ll be assigned to not

    more than one family, has been used to solve

    the GT grouping problem (Kusiak, 1987).

    Kusiaks similarity coefficients matrix has

    been used as input to an assignment model

    (Srinivasan et al ., 1990) to solve disjoint andnon-disjoint part famil ies problems. The part

    grouping problem in GT has been modelled as

    a linear transportation problem, solved in a

    two-phase algori thm to approximate the

    optimal solution (Kumar et a l., 1986). The p-

    median formulation (Mulvey and Crowder,

    1979) is an integer programming model wi th

    an objective function which seeks to min-

    imise the total sum of cluster-to-cluster

    median distances.

    Kumar et al ., (1986) formulated the GT

    grouping problem as an optimal k-decomposi-

    tion problem in graph theoretic terms in

    which decomposition of networks are consid-

    ered rather than block diagonalisation of

    matri ces. Lenstra (1974) formulated the clus-

    tering of a two-dimensional data array as

    equivalent to solving two travelling salesman

    problem. This problem has been mapped as a

    k-decomposition of weighted networks which

    is NP-complete (Ravikumar et a l., 1986).Several heuri stics which give polynomial

    bounds on the required computation time,

    but which do not guarantee optimal solution

    include Ballakur and Steudel (1987); Kumar

    and Vanell i (1987); Tabucannon and Ojha

    (1987), to mention a few.

    Other approaches that have been suggested

    by researchers include the use of neural net-

    works (Suresh and Kaparthi , 1994; Venugopal

    and Narendran, 1994), simulated annealing

    (Hindi and Haman, 1994; Venugopal and

    Narendran, 1992). For more on these see

    Singh and Rajamani (1996).The present study solves medium to large

    binary machine-part incidence matrix prob-

    lems and also another class of problems

    where machine uti li sations are considered,

    based on the simi larity order clustering

    (SOC) algorithm.

    The SOC procedure

    Determining similaritySimi larity coefficients (SCs) define relation-

    ships between pair s of machines or parts. The

    closer the relationship is, the higher the SC.

    The SCs are determined for both machines

    and parts from the machine-part incidence

    matrix. The SC used in the work reported in

    this paper is the one by Kusiak (1987).

    Kusiaks SC for machines is as follows:

    where si j

    is the similari ty coefficient between

    machines i andj, ai k

    is the machine-part inci-

    dence matrix value which is non-zero i f kthpart visits ith machine and is zero if other-

    wise. The diagonal values of the square simi-

    lari ty coefficient matrix are all zero. A simi-

    lar matrix is generated for parts.

    s d V d a a

    s V

    i j k i j

    k

    m

    ki k i j

    i j j

    = = =

    =

    =

    ; ,1

    1

    0

    if

    0 if otherwise

    Component family #1

    FMS

    Part family #1

    Component family #2

    Part family #2

    Component family #n

    Part family #n

    Figure 1

    Decomposition of FMS planning at

    disaggregation level

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    Based on Kusiaks coefficients, the SC

    between machines 3 and 4, s34 in Figure 2, can

    be calculated as follows: machines 3 and 4 do

    not process parts 2, 3, 5, 7, 8, 10, 11, 12, 13, 15and do process parts 1, 9, 14.S34 is therefore 10

    + 3 or 13. An si j

    is determined for all possible

    pairs of machines. The same procedure is

    followed for parts. The similari ty coefficients

    for machines in Table I are given in Table II .

    Using the SOC to obt ain machine and partsequencesSOC uses the order or rank of the simi larity

    coeffi cient value (SCV) to determine the best

    sequence for a given problem. Three steps are

    involved:

    1 Order the SCVs in a decreasing manner.2 Obtain the topology matrix.

    3 Generate the sequence from the topology

    matrix.

    Step 1 involves scanning the similarity coeffi -

    cient matrix given in Table II . It is useful to

    represent the simi larity coefficient matrix as

    a half-triangle, having values contained in

    the upper part of the diagonal and the lower

    part of the diagonal being zero. The SCVs are

    15, 14, 13, 7, 6, 5.

    Step 2 involves reading the row and column

    numbers of all ordered non-increasing SCVs

    into the topology matri x. For example, SCVs

    of 15 correspond to pairwise labels of (2, 5),(2, 8), (5, 8) and (7, 10). The first value corre-

    sponds to the row number whi le the second

    value of the pair cor responds to the column

    number in the similarity coefficient matrix.

    The topology matrix is given in Table III .

    In step 3, the first pair in the topology

    matrix are taken into the machine sequence.

    Hence in the first i teration in this step, the

    partial sequence array Q holds two machine

    labels: Q = {2, 5}. A closed loop is obtained by

    searching through the topology matrix, so

    that Q = {2, 5, 8}. This corresponds to

    machines in one cell C1= {2, 5, 8}. In the sec-ond iteration, the labels 2, 5, 8 are avoided

    during the search but a new pair in the topol-

    ogy matrix are chosen so that the partial

    sequence array Q holds two machine labels: Q

    = {7, 10}. A closed loop is obtained by search-

    ing through the topology matrix, so that Q =

    {7, 10, 1}. This corresponds to machines in

    another cell C2= {7, 10, 1}. In the thi rd itera-

    tion, the labels 2, 5, 8, 7, 10, 1 are avoided dur-

    ing the search but a new pair in the topology

    matrix are chosen so that the parti al

    sequence array Q holds two machine labels: Q

    = {3, 6}. A closed loop is obtained by search-

    ing through the topology matrix so that Q =

    {3, 6, 4, 9}. This corresponds to machines in a

    thi rd cell C3 = {3, 6, 4, 9}. Since the total num-

    ber of machines in all the cells are equal to

    the given number of machines, the algorithm

    terminates generating sequences for the

    machines. The same steps are followed for

    determining parts sequence. We note that the

    SOC determines the best sequence for

    machines within the SCV range of 15 and 14.

    The next lower SCV is 7 followed by the least

    value of 6. SOC ignores these because they are

    too low to give good machine clustering. Thi s

    results in the final machine-part matrix inTable IV. Machines {2, 5 and 8} form the first

    cell, machines {7, 10, 1} form the second cell

    and machines {3, 6, 4, 9} form the thi rd cell.

    The corresponding parts that form the three

    part-fami lies are {5, 3, 8, 13, 15}, {10, 2, 11, 12,

    7}and {14, 9, 1, 4, 6} respectively.

    Comparison with other algorithms

    Problem setIn order to test the effectiveness of the SOC

    procedure, eight problems from the li terature

    were used as a problem set. The differentproblems and their characteristics are shown

    in Table V. Problems 1, 3, 4, 5 and 6 were

    solved by Miltenburg and Zhang (1991) using

    nine different algorithms. The SOC

    Table II

    Similarity coefficients for the SOC example(aij=aji)

    M achine M achine

    1 2 3 4 5 6 7 8 9 10

    1 0 6 7 7 6 6 14 6 7 142 0 6 6 15 5 5 15 6 53 0 13 6 14 6 6 13 64 0 6 14 6 6 13 65 0 5 5 15 6 5

    6 0 5 5 14 57 0 5 6 158 0 6 59 0 6

    10 0

    Table IA 10 15 machine-part incidence matrix

    M achine Par t

    1 2 3 4 5 6 7 8 9 1 0 1 1 12 1 3 14 15

    1 0 1 0 0 0 0 0 0 0 1 1 1 0 0 02 0 0 1 0 1 0 0 1 0 0 0 0 1 0 13 1 0 0 0 0 1 0 0 1 0 0 0 0 1 04 1 0 0 1 0 0 0 0 1 0 0 0 0 1 05 0 0 1 0 1 0 0 1 0 0 0 0 1 0 16 1 0 0 1 0 1 0 0 1 0 0 0 0 1 07 0 1 0 0 0 0 1 0 0 1 1 1 0 0 08 0 0 1 0 1 0 0 1 0 0 0 0 1 0 19 0 0 0 1 0 1 0 0 1 0 0 0 0 1 0

    10 0 1 0 0 0 0 1 0 0 1 1 1 0 0 0

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    procedure results for these problems are

    compared to the results in that paper. In addi-

    tion, problems 2, 3, and 4 were solved by

    Askin et al . (1991) using the HPH method.

    Since they reported results better than that of

    the ROC2 algori thm, the SOC results from

    these problems are also compared to the HPH

    method results. Finally, problems 7 and 8

    were solved optimally by Wei and Gaither

    (1990). The SOC performances for these two

    problems are compared to the optimal solu-tions.

    Performance measures for cell groupingsolutionsThe quali ty of the solution presented in the

    form of machine-part incidence matrices is

    not immediately obvious. Therefore, a

    method is needed to compare these matrices

    using evaluation measures. Two measures

    used by Miltenburg and Zhang (1991) are used

    here. They are the grouping efficiency mea-

    sure the bond energy measure. These

    measures are chosen because together they

    measure the within-cell uti li sation, inter-cell

    movement, and the abili ty to cluster the non-

    zero entries of the machine-part incidence

    matri x together. Thus, they are comprehen-sive in their evaluation of cell grouping. The

    first measure is considered to be the primary

    measure, whi le the second measure is consid-

    ered to be a secondary measure.

    The grouping efficiency measure (e)Denoting the number of non-zero entr ies in

    the diagonal block (which form the cells) in

    the machine-part incidence matrix as n1,Miand P

    ias the number of machines and parts

    in each cell i, respectively, then

    whereCis the number of cells in the matrix

    and e1 is an indicator of the within-cell den-

    sity of a cell. Higher values ofe1show greater

    simi larity between the machines or parts in

    this cell , and ideally, it is expected that the

    whole cell be filled with non-zero entries. An

    inter-cell transfer indicator is defined as

    where n0 is the number of non-zero entri es in

    the machine-part incidence matrix outside

    the cells or inter-cell transfers. Lower values

    of n0and consequently values of e2 indicate

    fewer i nter-cell transfers and better solutions.

    The grouping efficiency is given as the differ-

    ence between e1and e2:

    In Table IV, there are three manufacturing

    cells with 15, 14 and 17 non-zero entries in

    each cell, respectively. The sum of these is 46

    (n1). The first two cells have three machines

    and five parts each, and the last cell has four

    machines and five parts. Summing the prod-ucts of the machines and parts for the three

    cells is 3 5 + 3 5 + 4 5 = 50. Thus, e1 is 46/ 50

    or 0.92. The number of inter-cell transfers, n0= 0, hencee2= 0. Thus, e= 0.92 0.0 = 0.92

    e e e e = 1 2 1 1 ,

    en

    n n2

    1

    1 0

    1=+

    ,

    en

    M Pi ii

    c11

    1

    =

    =

    ,

    Table III

    Topology matrix T (i,j) the for SOC example

    T ( i, j) 2,5 2,8 5,8 7,10 1,7 1,10 3,6 4,6 6,9 1,3 9,10 8,10SCV 15 15 15 15 14 14 14 14 14 7 6 5

    Table I V

    Cell grouping for 10 15 machine-incidence matrix of Figure 1

    M achine Par t5 3 8 13 15 10 2 11 12 7 14 9 1 4 6

    2 1 1 1 1 15 1 1 1 1 18 1 1 1 1 17 1 1 1 1 110 1 1 1 1 11 1 1 1 1 03 1 1 1 0 16 1 1 1 1 14 1 1 1 1 09 1 1 0 1 1

    Table VTest problem set

    M achine Par t s M at rix

    Number Problem (m) (n) densit ya

    1 Chan & Milner (1982) 15 10 0.312 De Witte (1980) 12 19 0.333 Chandrasekharan &

    Rajagopalan (1986b) 8 20 0.384 Burbridge (1975) 16 43 0.185 Carrie (1973) 20 35 0.196 Chandrasekharan &

    Rajagopalan (1986a) 8 20 0.577 Kumar and Vanelli (1987) 30 41 0.1058 King (1980) 14 24 0.175

    Note:aThe matrix density is given by [mn nj aij] / (mn) where aij0 in the

    machine-part incidence matrix, m is number of machines andn is number of parts.

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    Godfrey C. OnwuboluRedesigning jobshops tocellular manufacturing

    systemsIntegrated ManufacturingSystems9/ 6 [1998] 377382

    The bond energy measureClustering algorithms bri ng the non-zero

    entries of the machine-part i ncidence matrix

    close to each other. Thi s is essential ly theobjective of the bond energy algorithm (BEA).

    The strength of clustering can be computed

    byb, the normalised bond energy measure of

    a matrix given by

    Higher value bshows that the non-zero enter-

    ies of the machine-part incidence matrix are

    closely li nked. In the example in F igure 3, bis

    1.41.

    Results

    The results presented here for the SOC proce-

    dure are those obtained by visual analysis of

    the soluti ons provided. The results shown inTable VI compare the SOC results with the

    SC-seed of Miltenburg and Zhang (1991), the

    HPH method (Askin et al ., 1991) and 0-1 pro-gramming (Wei and Gaither, 1990). In Mil-

    tenburg and Zhang (1991), wi th respect to the

    five problems presented in the work reported

    here, the SC-seed performed best with respectto the grouping effi ciency measure. In prob-

    lems 1, 3, 5 and 6, the SOC grouping efficiencymeasure is vir tually identical to that of theSC-seed algori thm. Apart from problem 5, the

    SOC bond energy i s better than the SC-seed

    algorithm.In problem 3, the SOC grouping efficiency

    measure is the same HPH method but inferior

    for problem 4. In problems 7 and 8, the group-

    ing efficiency measure is better that the opti-mal solutions of the 0-1 programming algo-

    rithm in Wei and Gai ther (1990) where con-

    straints existed on the number of machines ina cell . In problem 7, where the constraint on

    the number of machines in a cell is 20 or less

    in Wei and Gaither (1990), the SOC procedure

    remains a four-cell solution, whi le the 0-1

    programming procedure identifies a two-cell

    solution.

    Conclusion

    The results of the experiments carri ed out

    show that the SOC procedure is effective for

    problems with different matrix densiti es. In

    all but one test problems established in the

    li terature, it performed well on the grouping

    measure which i s the primary measure of the

    quality of the solution. Thi s measure is an

    indicator of the abili ty of an algorithm to

    cluster random machine-part incidence

    matrices such that identification of cells

    becomes obvious. Since Wemmerlov and Hyer(1989) reported that may companies

    performed manual analysis of the machine

    cell grouping problem, the abili ty of an algo-

    ri thm to form clusters wil l ensure that good

    solutions to perform the manual analysis of

    cell formation that meet the requirements of

    the parti cular environment are available to

    the decision maker. The SOC procedure also

    informs the decision maker on the machine

    utili sation so that the number of machines

    required to meet the demand can be known

    before the actual implementation of the man-

    ufacturing system reconstruction from job-

    shop to manufacturing cells. The data

    required for determining the machine util isa-

    tion include the machine processing time for

    parts, setup time per batch, part batch sizes,

    period demand for parts and time available

    per machine per period.

    The SOC procedure is very attractive

    because of i ts simplicity and yet it i s quite

    effective. All that is required of the user is to

    create a data file containing the number of

    machines, number of parts and the machine-

    part incidence matrix. The SOC procedure

    dumps the solution in an output file which

    will then be accessed by the user. This is veryuseful, given that companies prefer simple

    but effective cell grouping procedures.

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    based heuristic for group technology configu-

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    b a a a a a ij i j ij i i j j

    n

    i

    m

    j

    n

    i

    m

    ij

    j

    n

    i

    m

    = +

    + +==

    =

    = == ( ) ( ) /1 1

    11

    1

    1

    1

    1 11

    Table VI

    Results

    SOC SC-see d HPH meth od 0 -1 p ro grammin g

    No. of

    Problem cells e1 e2 e b e b e b e b

    1 3 0.92 0.0 0.92 1.41 0.93 1.37 2 2 0.57 0.28 0.29 1.0 3 3 1.0 0.15 0.85 1.34 0.85 1.31 0.85 1.38 4 2 0.3 0.2 0.14 0.63 0.45 1.02 0.42 1.11 5 4 0.87 0.21 0.66 1.18 0.76 1.40

    6 1 0.57 0.0 0.57 1.10 0.57 1.21 2 0.77 0.37 0.40 0.83 7 4 0.39 0.13 0.26 0.60 0.16a 0.918 2 0.62 0.29 0.33 0.67 0.33 1.08Note: aTwo cell solution

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