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    Flow Analysis

    Factors that Affect the Flow Pattern

    Flow Analysis Information

    Flow Patterns

    a. Flow within Workstations b. Flow within Departments

    c. Flow between Departments Flow Planning

    Measuring Flow

    Types of Layout

    a. Fixed Location b. Product

    c. Group Technology d. Processe. Hybrid

    Flow Dominance Measure

    Techniques for Machine Cell Formation

    a. Row and Column Masking Algorithm

    b. Single Linkage Clustering c. Average Linkage clustering

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    Factors that Affect the Flow Pattern

    Number of parts in each product

    Number of operations on each part

    Sequence of operations in each part

    Number of subassemblies

    Number of units to be produced

    Product versus process type layout

    Desired flexibility

    Locations of service areas The building

    . . . .

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    Flow Analysis Information

    Assembly Chart

    Operations Process Chart

    Flow Process Chart

    Multi-Product Process Chart

    Flow Diagram

    From-To Chart

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    Assembly Chart

    It is an analog model of the assembly

    process. Circles with a single link denote

    basic components, circles with several

    links denote assemblyoperations/subassemblies, and squares

    represent inspection operations. The

    easiest method to constructing an

    assembly chart is to begin with the

    original product and to trace the product

    disassembly back to its basic components.

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    Operations Process Chart

    By superimposing the route sheets and

    the assembly chart, a chart results that

    gives an overview of the flow within

    the facility. This chart is operations

    process chart.

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    Flow Process Chart

    This chart uses circles for

    operations, arrows for transports,squares for inspections, triangles

    for storage, and the letter D for

    delays. Vertical lines connect these

    symbols in the sequence they are

    performed.

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    Multi-Product Process Chart

    This chart is a flow process chart

    containing several products.

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    Flow Diagram

    It depicts the probable

    movement of materials in thefloor plant. The movement is

    represented by a line in the plant

    drawing.

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    From-To Chart

    This chart is a matrix that

    contains numbers representing ameasure (units, unit loads, etc.)

    of the material flow between

    machines, departments,

    buildings, etc.

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    Flow Patterns: Flow within Workstations

    Motion studies and ergonomics considerations are important in

    establishing the flow within workstations. Flow within workstations

    should be:

    Simultaneous: coordinated use of hands, arms and feet.

    Symmetrical: coordination of movements about the center of the

    body.

    Natural: movements are continuous, curved, and make use of

    momentum.

    Rhythmical and Habitual: flow allows a methodological and

    automatic sequence of activities. It should reduce mental, eye and

    muscle fatigue, and strain.

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    Flow Patterns: Flow within Departments

    The flow pattern within departments depends on the type of

    department.

    In a product and/or product family department, the flow follows the

    product flow.1 machine/operator

    1 machine/operator 2 machines/operator

    1 machine/operator

    More than 2

    machines /operator

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    Flow Pat.: Flow within Departments (cont.)

    In a process department, little flow should occur between workstations

    within departments. Flow occurs between workstations and isles.

    Aisle

    Aisle

    Aisle

    Aisle

    Aisle

    Dependent on interactions among workstations

    available space

    size of materials

    Uncommon

    One way

    One way

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    Flow Pat.: Flow between Departments

    Flow between departments is a criterion often used to evaluate flow

    within a facility.

    Flow typically is a combination of the basic horizontal flow patterns

    shown below. An important consideration in combining the flow

    patterns is the location of the entrance (receiving department) and exit

    (shipping department).

    Straight

    U flow

    Serpentine

    L flow

    S flow

    Circularflow

    Simplest. Separate

    receiving/shipping

    crews

    Very popular.

    Combine receiving/shipping. Simple to

    administer

    When line is too long

    Similar to straight.

    It is not as long.

    Terminate flow.Near point of origin

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    Flow within a facility considering the

    locations of entrance and exit

    At the same location

    On adjacent sides

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    Flow within a facility considering the

    locations of entrance and exit (cont.)

    On the same side but

    at opposite ends

    On opposite sides

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    Vertical Flow Pattern

    Flow between buildings exists

    and the connection between

    buildings is elevated

    Ground level ingress (entry)

    and egress (exit) are required

    Ground level ingress (entry)

    and egress (exit) occur on the

    same side of the building

    Travel between floors occurs on

    the same side of the building

    Some bucket and belt

    conveyors and escalators result

    in inclined flow

    Backtracking occurs due to the

    return to the top floor

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    Flow Planning

    Planning effective flow involves combining the above patterns with adequate isles

    to obtain progressive movements from origin to destination.

    An effective flow can be achieved by maximizing directed flow paths, reducing

    flow, and minimizing the costs of flow.

    A directed flow path is an uninterrupted flow path progressing directly from

    origin to destination: the Figure below illustrates the congestion and undesirableintersections that may occur when flow paths are interrupted.

    Uninterrupted flow paths

    Interrupted flow paths

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    Flow Planning (cont.)

    The reduction of flow can be achieved by work simplification including:

    1. Eliminating flow by planning for the delivery of materials, information, or people

    directly to the point of ultimate use and eliminate intermediate steps.

    2. Minimizing multiple flows by planning for the flow between two consecutive points

    of use to take place in as few movements as possible.

    3. Combining flows and operations whenever possible by planning for the movement of

    materials, information, or people to be combined with a processing step.

    Minimizing the cost of flow can be achieved as follows:

    1. Reduction of manual handling by minimizing walking, manual travel distances, and

    motions.

    2. Elimination of manual handling by mechanizing or automating flow.

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    Measuring Flow

    1. Flow among departments is one of the most important factors in the arrangement of departments

    within a facility.

    2. Flows may be specified in a quantitative manner or a qualitative manner. Quantitative measures

    may include pieces per hour, moves per day, pounds per week. Qualitative measures may range

    from an absolute necessity that two departments show be close to each other to a preference that

    two departments not being close to each other.

    3. In facilities having large volumes of materials, information, a number of people moving between

    departments, a quantitative measure of flow will typically be the basis for the arrangement of

    departments. On the contrary, in facilities having very little actual movement of materials,

    information, and people flowing between departments, but having significant communication

    and organizational interrelation, a qualitative measure of flow will typically serve as the basisfor the arrangement of departments.

    4. Most often, a facility will have a need for both quantitative and qualitative measures of flow and

    both measures should be used.

    5. Quantitative flow measure: From-to Chart

    Qualitative flow measure: Relationship (REL) Chart

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    Quantitative Flow Measurement

    A From-to Chart is constructed as follows:

    1. List all departments down the row and across the column following the overall

    flow pattern.

    2. Establish a measure of flow for the facility that accurately indicates equivalent

    flow volumes. If the items moved are equivalent with respect to ease of movement,

    the number of trips may be recorded in the from-to chart. If the items moved vary

    in size, weight, value, risk of damage, shape, and so on, then equivalent items may

    be established so that the quantities recorded in the from-to chart represent theproper relationships among the volumes of movement.

    3. Based on the flow paths for the items to be moved and the established measure of

    flow, record the flow volumes in the from-to chart.

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    Example 1

    Stores

    Turning

    Milling

    Press

    Plate

    Assembly

    Warehouse

    6 12 9 1 4

    3 4

    7 2

    3 1 1

    1 3 4 3

    1 7

    Stores

    Turning

    Milling

    Press

    Plate

    Assembly

    Warehouse

    Stores

    Milling

    Turning

    Press

    Plate

    Assembly

    Warehouse

    12 6 9 1 4

    7 2

    3 4

    3 1 1

    3 1 4 3

    1 7

    Stores

    Milling

    Turning

    Press

    Plate

    Assembly

    Warehouse

    From-to Chart

    Original Flow Pattern Revised Flow Pattern

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    Flow Patterns

    Store

    Turning

    Milling

    Press

    Plate

    Assembly

    Warehouse

    Stores Turning Milling

    Warehouse Assembly Plate

    Press

    Stores Press Plate Assembly

    Turning Milling Warehouse

    Stores Milling Warehouse

    Turning Press Plate Assembly

    Straight-line flow U-shaped flow

    W-shaped flowS-shaped flow

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    Flow Patterns (cont.)

    Store

    Turning

    Milling

    Press

    Plate

    Assembly

    Warehouse

    Stores Turning Milling

    Warehouse Assembly Plate

    Press

    Stores Press Plate Assembly

    Turning Milling Warehouse

    Stores Milling Warehouse

    Turning Press Plate Assembly

    Straight-line flow U-shaped flow

    W-shaped flowS-shaped flow

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    Qualitative Flow Measurement

    A Relationship (REL) Chart is constructed as follows:

    1. List all departments on the relationship chart.

    2. Conduct interviews of surveys with persons from each department listed on the

    relationship chart and with the management responsible for all departments.

    3. Define the criteria for assigning closeness relationships and itemize and record the

    criteria as the reasons for relationship values on the relationship chart.

    4. Establish the relationship value and the reason for the value for all pairs of

    departments.

    5. Allow everyone having input to the development of the relationship chart to have

    an opportunity to evaluate and discuss changes in the chart.

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    Relationship Chart

    Code Reason

    1 Frequency of use high

    2 Frequency of use medium

    3 Frequency of use low

    4 Information flow high

    5 Information flow medium

    6 Information flow low

    Rating Definition

    A Absolutely Necessary

    E Especially Important

    I Important

    O Ordinary Closeness OK

    U Unimportant

    X Undesirable

    1. Directors conference room

    2. President

    3. Sales department

    4. Personnel

    5. Plant manager

    6. Plant engineering office

    7. Production supervisor

    8. Controller office

    9. Purchasing department

    I

    1

    O

    5

    U

    6

    O

    5

    A

    4

    I

    4

    U

    6

    I

    4

    I

    1

    U

    6

    I

    4

    O

    5

    A

    4

    O

    5

    O

    5

    U

    3

    O

    5

    O

    5

    O

    5

    O

    5

    E

    4

    O

    2

    U

    6

    O

    5

    O

    5

    O

    5

    U

    3

    U

    6

    E

    4

    O

    4

    U

    3

    I

    4

    I

    4

    U

    3

    O

    5

    U

    6

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    Types of Layout

    Volume

    High

    Medium

    Low

    Low Medium High Variety

    Product

    Planning

    Department

    Fixed MaterialsLocation

    Planning

    Department

    ProcessPlanning

    Department

    Product

    Family

    Planning

    Department

    Product

    Layout

    Fixed Location

    Layout

    Group Technology

    Layout

    Process

    Layout

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    Fixed Product Layout

    Lathe Press Grind

    Weld AssemblyPaint

    St

    o

    r

    a

    g

    e

    W

    a

    r

    e

    h

    o

    u

    s

    e

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    Fixed Product Layout (cont.)

    Advantages

    1. Material movement is reduced.

    2. Promotes job enlargement by allowing individuals or teams to perform the whole job.

    3. Continuity of operations and responsibility results from team.

    4. Highly flexible; can accommodate changes in product design, product mix, and product volume.

    5. Independence of production centers allowing scheduling to achieve minimum total production

    time.

    Limitations

    1. Increased movement of personnel and equipment.

    2. Equipment duplication may occur.

    3. Higher skill requirements for personnel.4. General supervision required.

    5. Cumbersome and costly positioning of material and machinery.

    6. Low equipment utilization.

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    Product Layout

    Drill Grind Drill

    Lathe

    Drill

    Drill

    St

    o

    r

    a

    g

    e

    W

    a

    r

    e

    h

    o

    u

    s

    e

    As

    s

    e

    m

    b

    l

    y

    Lathe

    Bend

    Lathe

    Mill

    Press

    Drill

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    Product Layout (cont.)

    Advantages

    1. Since the layout corresponds to the sequence of operations, smooth and logical flow lines result.

    2. Since the work from one process is fed directly into the next, small in-process inventories result.

    3. Total production time per unit is short.

    4. Since the machines are located so as to minimize distances between consecutive operations, material

    handling is reduced.

    5. Little skill is usually required by operators at the production line; hence, training is simple, short,

    and inexpensive.

    6. Simple production planning control systems are possible.

    7. Less space is occupied by work in transit and for temporary storage.

    Limitations1. A breakdown of one machine may lead to a complete stoppage of the line that follows that machine.2. Since the layout is determined by the product, a change in product design may require major

    alternations in the layout.

    3. The pace of production is determined by the slowest machine.

    4. Supervision is general, rather than specialized.

    5. Comparatively high investment is required, as identical machines (a few not fully utilized) are

    sometimes distributed along the line.

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    Process Layout

    Lathe Drill Weld

    Mill

    Drill

    Grind

    St

    o

    r

    a

    g

    e

    W

    a

    r

    e

    h

    o

    u

    s

    e

    Lathe

    Lathe

    Mill

    Mill

    Lathe

    Mill

    Paint

    Grind

    Assembly

    Assembly

    Paint

    Weld

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    Process Layout (cont.)

    Advantages

    1. Better utilization of machines can result; consequently, fewer machines are required.

    2. A high degree of flexibility exists relative to equipment or man power allocation for specific

    tasks.

    3. Comparatively low investment in machines is required.

    4. The diversity of tasks offers a more interesting and satisfying occupation for the operator.

    5. Specialized supervision is possible.

    Limitations1. Since longer flow lines usually exist, material handling is more expensive.

    2. Production planning and control systems are more involved.

    3. Total production time is usually longer.4. Comparatively large amounts of in-process inventory result.

    5. Space and capital are tied up by work in process.

    6. Because of the diversity of the jobs in specialized departments, higher grades of skill are

    required.

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    Group Layout

    Drill Grind Assembly

    Drill

    Weld

    Assembly

    St

    o

    r

    a

    g

    e

    W

    a

    r

    e

    h

    o

    u

    s

    e

    Lathe

    Assembly

    Grind

    Press

    Mill

    Lathe

    Paint

    Drill

    Drill

    Press

    Grind

    Assembly

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    Group Layout (cont.)

    Advantages

    1. Increased machine utilization.

    2. Team attitude and job enlargement tend to occur.

    3. Compromise between product layout and process layout, with associated advantages.

    4. Supports the use of general purpose equipment.5. Shorter travel distances and smoother flow lines than for process layout.

    Limitations1. General supervision required.

    2. Higher skill levels required of employees than for product layout.

    3. Compromise between product layout and process layout, with associated limitations.

    4. Depends on balanced material flow through the cell; otherwise, buffers and work-in-processstorage are required.

    5. Lower machine utilization than for process layout.

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    Hybrid Layout

    Combination of the layouts discussed.

    A sample hybrid layout that has characteristics of group, process and product

    layout is shown in the following figure.

    A combination of group layout in manufacturing cells, product layout in assembly

    area, and process layout in the general machining and finishing section is used.

    TM

    TM TM

    TM TMDM

    BM

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    Flow Dominance Measure

    Notations:

    M: number of activities.

    Nij: number of different types of items moved between activities i and j.

    fijk: flow volume between i and j for item k (in moves/time period).

    hijk: equivalence factor for moving item k with respect to other items moved

    between i and j (dimensionless).

    wij: equivalent flow volume specified in from-to chart (in moves/time period),

    w = f h .ij ijk ijk k

    N ij

    1

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    Flow Dominance Measure (cont.)

    Flow dominance measure = f =

    where

    f f

    f f

    U

    '

    U L

    f

    w M w

    M 1

    w, w =

    w

    M

    f MM M 1

    (M 1)(M 1), f M

    1

    (M 1)(M 1)

    '

    ij

    2 2 2

    j 1

    M

    i 1

    M

    2

    1

    2

    ijj 1

    M

    i 1

    M

    2

    U

    2

    2 L 2

    1

    2

    1

    2

    fis the coefficient of variation. fL and fU are lower and upper bounds on f, respectively (fL f fU).

    The upper bound fU is only guaranteed to work when each process plan includes all

    activities. In this case, 0 f 1.

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    Flow Dominance Measure (cont.)

    Three cases :

    1. f 0 a few dominant flows exist. product layout.

    can use operations process chart as starting point for developing layout and

    material handling system design. quantitative measures principal source of activity relationship.

    2. f 1 many nearly equal flows exist.

    any layout equally good with respect to flows .

    qualitative measures principal source of activity relationship.

    3. 0

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    Example 2

    Given three machines (activities) labeled 1, 2 & 3,

    Product

    A

    B

    C

    Process Plan

    1 - 2 - 3

    2 - 1

    3 - 1 - 2

    Quantities/Shift

    10

    5

    15

    Assume Product B is twice as difficult to move as A or C hijB = 2 and hijA = hijC = 1

    To

    From

    1

    2

    3

    1

    0

    2 5

    10

    1 15

    15

    2

    110

    1 1525

    0

    0

    3

    0

    1 10

    10

    0

    Equivalent

    Flow Volume

    From-To Chart

    w12 = 25,

    w21 = 10, etc

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    Example 2 (cont.)

    M = 3 and

    f3 1

    6.67= .352

    f 33 3 1

    (3 1)(3 1)

    = 1.984 and f 31

    (3 1)(3 1)

    f

    '

    2

    U

    2

    2 L 2

    ( ) ( . )

    .

    . .

    . ..

    25 10 10 15 3 6 67

    1

    0 75

    1984 1352

    1984 0 7505122

    2 2 2 2 2 212

    1

    2

    1

    2

    w =(25 10 10 15)

    36.672

    no dominant flows exist

    (likely, since 3 different process plans)

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    Qualitative Measures

    Closeness values (A, E, I, O, U, X) used to indicate physical proximity

    requirements between activities.

    Relationship Chart can only show symmetric relationships, as compared to

    From-to Chart (wij wji possible).

    Relationship Chart is starting point for developing layout when 0

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    Conversion Method

    To convert equivalent flow volumes to closeness values for the example

    problem, use wij + wji to make them symmetric.

    Conversion relations :

    20 < wij + wji A w12 + w21 = 25 + 15 A

    12 < wij + wji 20 E w13 + w31 = 0 + 15 E

    5 < wij + wji 12 I w23 + w32 = 10 + 0 I

    0 < wij + wji 5 O

    wij + wji = 0 U

    A

    IE

    Machine 1

    Machine 2

    Machine 3

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    Group Technology

    Group Technology (GT) is a management philosophy that attempts to group

    products with similar design or manufacturing characteristics, or both.

    Cellular Manufacturing (CM) is an application of GT that involves grouping

    machines based on the parts manufactured by them.

    The main objective of CM is to identify machine cells and part families

    simultaneously, and to allocate part families to machine cells in a way that

    minimizes the intercellular movement of parts.

    Potential benefits of CM:

    * Setup time reduction. * Improvement in quality.

    * Work-in-process (WIP) reduction. * Improvement in material flow.* Material handling cost reduction. * Improvement in machine utilization.

    * Direct/indirect labor cost reduction. * Improvement in space utilization.

    * Improvement in employee moral.

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    Group Technology (cont.)

    A cellular manufacturing system (CMS) designer must consider a number of

    constraints:

    Available capacity of machines in each cell cannot be exceeded.

    Safety and technological requirements pertaining to the location of equipment and

    processes must be met. The size of a cell and the number of cells must not exceed a user-specified value.

    Design analysis begins with a machine-part indicator matrix A = [aij] of size

    mn, where m is the number of machines and n the number of parts.

    Typically the matrix consists of 0 and 1 entries:

    aij = 1 indicates that part j is processed by machine i.

    aij = 0 indicates that part j is not processed by machine i.

    Analysis attempt to rearrange the rows and columns of the matrix to get a

    block diagonal form as shown in the following example.

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    Example 3

    Initial Machine Part

    Processing Matrix

    Rearranged Machine-Part

    Processing Matrix

    P1 P2 P3 P4P5 P6

    M1

    M2

    M3

    M4

    M5

    M6

    M7

    1

    1 1 1

    1 11

    1 1

    1

    1

    1 1

    Part

    Ma

    chine

    P1 P3 P2 P4P5 P6

    M1

    M4

    M6

    M2

    M3

    M5

    M7

    1

    1 1

    1 1

    1 1 1

    1 11

    1

    Part

    Ma

    chine

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    Row and Column Masking (R&CM) Algorithm

    1. Draw a horizontal line through the first row. Select any 1 entry in the matrix

    through which there is only one line.

    2. If the entry has a horizontal line, go to step 2a. If the entry has a vertical line,

    go to step 2b.

    2a. Draw a vertical line through the column in which this 1 entry appears. Go to

    step 3.

    2b. Draw a horizontal line through the row in which this 1 entry appears. Go to

    step 3.

    3. If there is any 1 entries with only one line through them, select any one and go

    to step 2. Repeat until there are no such entries left. Identify the correspondingmachine cell and part family. Go to step 4.

    4. Select any row through which there is no line. If there are no such rows, stop.

    Otherwise, draw a horizontal line through this row, select any 1 entry in the

    matrix through which there is only one line, and go to step 2.

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    Example 3 Solution

    Identification of the First Machine

    Cell and Part Family

    Identification of the Second Machine

    Cell and Part Family

    P1 P2 P3 P4P5 P6

    M1

    M2

    M3

    M4

    M5

    M6

    M7

    1

    1 1 1

    1 11

    1 1

    1 1

    1 1

    Part

    Machine

    2

    3

    4

    1 5

    P1 P2 P3 P4P5 P6

    M1

    M2

    M3

    M4

    M5

    M6

    M7

    1

    1 1 1

    1 11

    1 1

    1 1

    1 1

    Part

    Machine

    2

    3

    4

    7

    1 5 8

    6

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    Single Linkage (S-Link) Clustering Algorithm

    S-Link is the simplest of all clustering algorithms based on the similarity

    coefficient method.

    The similarity coefficient between two machines is defined as the number of

    parts visiting the two machines divided by the number of parts visiting either

    of the two machines.

    1. pairwise similarity coefficients between machines are calculated and stored in

    the similarity matrix.

    2. The two most similar machines join to form the first machine cell.

    3. The threshold value (the similarity level at which two or more machine cellsjoin together) is lowered in predetermined steps and all machine/machine cells

    with the similarity coefficient greater than the threshold value are grouped into

    larger cells.

    4. Step 3 is repeated until all machines are grouped into a single machine cell.

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    Example 4: Initial Machine Part Matrix

    P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22

    M1

    M2

    M3

    M4

    M5

    M6

    M7

    M8

    M9

    M10

    M11

    1 1 1 1 1 1 1

    1 1

    1 1 1 1 1

    1 1 1 1 1

    1 1 1 1 1 1 1

    1 1

    1 1 1 1 1 1 1

    1 1

    1 1 1 1

    1 1 1 1 1 1

    Part

    Machine

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    Example 4: Initial Similarity Coefficient Matrix

    M1 M2 M3 M4 M5 M6 M7M8 M9 M10 M11

    M1

    M2

    M3

    M4

    M5

    M6

    M7

    M8

    M9

    M10

    M11

    0.08

    0.00 0.43

    1.00 0.08 0.00

    0.80 0.00 0.00 0.80

    0.00 0.80 0.50 0.00 0.00

    0.00 0.00 0.10 0.00 0.00 0.00

    0.00 0.25 0.50 0.00 0.00 0.27

    0.45

    0.00 0.00 0.00 0.00 0.00 0.00

    0.83 0.36

    0.43 0.45 0.23 0.43 0.43 0.36

    0.00 0.17 0.00

    Machine

    Machine

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    Example 4: Dendrogram Based on S-Link

    M1 M4 M5 M2 M6 M3 M8M10 M7 M9 M11

    Machine

    0.00

    0.25

    0.50

    0.75

    1.00

    Similarity

    Levels

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    Example 4: Machine Part Groups using S-Link

    P1 P3 P16 P2 P15 P22 P20 P21 P7 P11 P8 P19 P5 P12 P13 P6 P14 P18 P9 P10 P17 P4

    M5

    M1

    M4

    M10

    M2

    M6

    M3

    M8

    M7

    M9

    M11

    1 1 1 1 1 1 1 1 1

    1 1 1 1 1 1 1 1 1

    1 1 1 1 1 1 1 1 1

    1 1 1 1 1 1 1 1 1 1 1

    1 1 1 1 1

    1 1 1 1

    1 1 1 1 1

    Part

    Machine

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    Average Linkage (A-Link) Clustering Algorithm

    The similarity coefficient between two machine cells is defined as the average

    of pairwise similarity coefficients between all members of the two cells.

    1. Compute pairwise similarity coefficients between machines and construct the

    similarity coefficient matrix.

    2. Merge the two most similar machines into a single machine cell.

    3. Compute the similarity coefficients between the newly formed machine cell

    and the remaining cells. Revise the similarity coefficient matrix.

    4. The threshold value (the similarity level at which two or more machine cells

    join together) is lowered in predetermined steps and all machine/machine cellswith the similarity coefficient greater than the threshold value are grouped into

    larger cells. Repeat steps 3 and 4 until all machines are grouped into a single

    machine cell.

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    Example 4: Revised Similarity Coefficient Matrix I

    (M1,M4) (M2,M6) M3 M5 (M7,M9) M8 M10 M11

    (M1,M4)

    (M2,M6)

    M3

    M5

    (M7,M9)

    M8

    M10

    M11

    0.04

    0.00 0.47

    0.80 0.00 0.00

    0.00 0.00 0.05 0.00

    0.00 0.26 0.50 0.00 0.41

    0.43 0.41 0.23 0.43 0.00 0.17

    0.00 0.00 0.00 0.00 0.62 0.36 0.00

    Machine Cell

    MachineCell

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    Example 4: Revised Similarity Coefficient Matrix II

    (M1,M4 ,M5) (M2,M6) M3 (M7,M9,M11) M8 M10

    (M1,M4,M5)

    (M2,M6)

    M3

    (M7,M9,M11)

    M8

    M10

    0.02

    0.00 0.47

    0.00 0.00 0.03

    0.00 0.26 0.50 0.39

    0.43 0.41 0.23 0.00 0.17

    Machine Cell

    MachineCell

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    Example 4: Revised Similarity Coefficient Matrices III & IV

    (M1,M4 ,M5) (M2,M6) (M3,M8) (M7,M9,M11)M10

    (M1,M4,M5)

    (M2,M6)

    (M3,M8)

    (M7,M9,M11)

    M10

    0.02

    0.00 0.37

    0.00 0.00 0.21

    0.43 0.41 0.20 0.00

    Machine Cell

    Machin

    eCell

    (M1,M4,M5,M10) (M2,M6, M3,M8) (M7,M9,M11)

    (M1,M4,M5,M10)

    (M2,M6, M3,M8)

    (M7,M9,M11)

    0.02

    0.00 0.11

    Machine Cell

    MachineCell

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    Example 4: Dendrogram Based on A-Link

    M1 M4 M5 M10 M2 M6 M3M8 M7 M9 M11

    Machine

    0.00

    0.25

    0.50

    0.75

    1.00

    Similarity

    Levels

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    Example 4: Machine Part Groups using A-Link

    P1 P3 P16 P2 P15 P22 P20 P21 P7 P11 P8 P19 P5 P12 P13 P6 P14 P18 P9 P10 P17 P4

    M5

    M1

    M4

    M10

    M2

    M6

    M3

    M8

    M7

    M9

    M11

    1 1 1 1 1 1 1 1 1

    1 1 1 1 1 1 1 1 1

    1 1 1 1 1 1 1 1 1

    1 1 1 1 1 1 1 1 1 1 1

    1 1 1 1

    1 1 1 1

    1 1 1 1 1

    Part

    Machine

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    Comparison

    R&CM is the simplest clustering algorithm.

    A major disadvantage of R&CM is that when the machine part matrix contains one or more

    bottleneck machines (machines that belong to more than one cell) or exceptional parts (parts

    that are processed in more than one cell), the algorithm may provide a solution with all

    machines in a cell and all parts in a corresponding part family.

    The major advantages of S-Link are its simplicity and minimal computational requirement.In S-Link, once pairwise similarity coefficients are computed and the similarity coefficient

    matrix is constructed, the matrix can be used to develop the dendrogram which represents

    the machine cells at different threshold values.

    The major drawback of S-Link is the chaining problem. Due to the chaining problem, two

    machine cells may join together just because two of their members are similar while the

    remaining members may remain far apart in terms of similarity.

    The chaining problem of S-Link can be overcome by using A-Link. Since in A-Link two

    machine cells merge based on the overall similarity coefficient between all their members, it

    is unlikely that two similar members in two cells cause the cells to merge while other

    members are not similar enough. A-Link provides a more reliable solution to the machine