Optimization of a Dynamic Cellular Manufacturing System Considering Machine Breakdowns along with Sequence Monitoring of Operation Periods

Document Type : Research Paper


1 MSc. Student, Department of Industrial Management, Faculty of Business and Economics, Persian Gulf University, Bushehr, Iran

2 , Associate Prof., Department of Industrial Management, Faculty of Business and Economics, Persian Gulf University, Bushehr, Iran.

3 Assistant Prof., Department of Industrial Management, Faculty of Business and Economics, Persian Gulf University, Bushehr, Iran


Short product life cycles, unpredictable demand patterns, and ever-decreasing time-to-market have put manufacturing companies under pressure. To face all complex production scenarios, these companies tend to the implementation of Cellular Manufacturing Systems (CMS) to reduce production costs, increase flexibility, and respond quickly to market demands. The cellular manufacturing system facilitates the control and management of the production system by dividing a large system into several small subsystems. The design of a cellular manufacturing system includes cell formation, group layout, group scheduling, and resource allocation. The first issue in designing a cellular system is the grouping of machines to produce a family of parts in production cells referred to as cell formation. The creation of efficient cells aims to achieve maximum performance of intracellular machines (intra-cellular processes) and minimize the transfer of parts from one cell to another (inter-cellular processes). The second problem is the problem of group layout, which includes the placement of cells in the workshop relative to each other (intercellular layout) and the layout of machines within the cells (intracellular layout). The optimal grouping of machines in cells, the efficient placement of cells relative to each other, as well as the machines inside cells affect the cost of intracellular movements and intercellular movements of parts. Considering that in a static cellular manufacturing system, the demand is considered constant in all periods, however, due to the advancement of technology, the environment of an industry is faced with turbulence in the types of products and demand. To overcome these problems, a dynamic cellular manufacturing system was introduced, which forms optimal cells in each period according to the demand conditions and changes in product composition. This study addresses the simultaneous challenges of a dynamic cellular manufacturing system (DCMS) with unreliable machines and production planning and intercellular layout problems. The proposed model seeks to minimize the costs of Inter and intra-cellula movement, reconfiguration, machine breakdown, part production, keeping parts in the warehouse, and back-ordering parts in production cycles.
At first, a mixed integer nonlinear programming mathematical model for the considered problem was presented, Next, linearized and validated with a case study in GAMS software with a GUROBI solver. In the following, the impact of moving machines between periods and the sensitivity analysis of the MTBF parameter were discussed.
Flexibility in routing, optimal location of cells, and optimal grouping of machines reduced production costs, and also by moving two machines m1 and m3, production costs improved by 353,870 Tomans.
The reconfiguration of machine cells in the new period improves the cost of production and also the model is flexible in routing part production. In this study, MTBF sensitivity analysis showed that the number of failures affects the system's performance.


Main Subjects

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