• ISSN: 2148-2225 (online)

Ulaştırma ve Lojistik Kongreleri

alphanumeric journal

The Journal of Operations Research, Statistics, Econometrics and Management Information Systems

Cellular Manufacturing Systems: Organization, Trends and Innovative Methods


A. Attila İşlier


Abstract

Interchangeability is the distinguishing feature of modern manufacturing. A huge production capacity to satisfy the people is reached thanks to that concept. Yet that prospect brought up a dilemma too. Efficient but inflexible flow lines for very limited product types on one side and unproductive flexible batch production for numerous diverse parts on the other side. The remedy is thought of as Cellular Manufacturing (CM). That seemed a brilliant idea but the proliferation of CM has never reached to the expected levels. This paper discusses the probable causes of this discontent by referring both academic and practical issues and tries to give some clues to improve the achievements of further CM applications by emphasizing of the contemporary tools like computer techniques, especially emerging approaches of artificial intelligence as well as organizational and social issues.

Keywords: Cellular Manufacturing, Group Technology, Production Systems

Jel Classification: D2, L61, O33

Hücresel Üretim Sistemleri: Yapı, Eğilimler ve Yenilikçi Yöntemler


Öz

Montajda kullanılan parçalardaki değiştirilebilirlik, modern imalatın belirgin bir niteliği olmuştur. Günümüz insanlarına doyum sağlayacak muazzam bir üretim gücüne de yine bu kavram sayesinde erişilebilmiştir. Ancak bu kavramdan yararlanma gayretleri, bir ikilemi de beraberinde getirmiştir. Bir yanda değiştirilebilirlik sayesinde yüksek verimlilikle ama son derece sınırlı tipte ürün üreten ve esnek olmayan seri üretim hatları diğer yanda da çeşit çeşit ürünü üretebilen esnek ama verimsiz parti tipi üretim sistemleri ortaya çıkmıştır. Her iki üretim tipinin üstün yanlarını birleştirecek çare de, uzun bir süreden beri Hücresel Üretim (HÜ) olarak görülmüştür. Fakat ilk bakışta, çok parlak bir düşünce olarak görünen bu yaklaşım da, hiçbir zaman kendinden beklenen hızla yaygınlaşamamıştır. Bu makalenin amacı da, buradaki çelişkinin kuramsal ve uygulamaya yönelik kaynaklarını irdeleyip, özellikle bilgisayar gibi araçlar ve yapay zekâ gibi yeni tekniklerin sağlayacağı olanaklar yanında işin örgütsel ve toplumsal yönlerini vurgulayarak HÜ uygulamalarındaki başarı düzeyini yükseltebilecek bazı ipuçlarını ortaya koymak olmuştur.

Anahtar Kelimeler: Grup Teknolojisi, Hücresel Üretim, Üretim Sistemleri


Suggested citation

İşlier, A. A. (). Cellular Manufacturing Systems: Organization, Trends and Innovative Methods. Alphanumeric Journal, 3(2), 13-26. http://dx.doi.org/10.17093/aj.2015.3.2.5000140019

bibtex

References

  • Ahi, A., Aryanezhad, M. B., Ashtiani, B.& Makui, A. (2009.) A novel approach to determine cell formation, intracellular machine layout and cell layout in the CMS problem based on TOPSIS method. Computers & Operations Research, 36, 1478 – 1496.
  • Akturk, M. S. & Yayla, H. M. (2006). Management of product variety in cellular manufacturing systems. International Journal of Flexible Manufacturing Systems, 17, 93–117.
  • Ameli, M. S. J. & Arkat, J. (2008). Cell formation with alternative process routings and machine reliability consideration. International Journal of Advanced Manufacturing Technology, 35, 761–768.
  • Andrés, C.& Lozano, S. (2006). A particle swarm optimization algorithm for part–machine grouping. Robotics and Computer-Integrated Manufacturing, 2, 468–474.
  • Andrés, C., Lozano, S.& Diaz, B. A., (2007). Disassembly sequence planning in a disassembly cell context. Robotics and Computer-Integrated Manufacturing, 23, 690–695.
  • Angra, S., Sehgal, R.& Noori, Z. S. (2008). Cellular manufacturing—A time-based analysis to the layout problem. International Journal of Production Economics, 112, 427–438.
  • Arkat J., Saidi, M. & Abbasi, B. (2007). Applying simulated annealing to cellular manufacturing system design. International Journal of Advanced Manufacturing Technology, 32, 531–536.
  • Baykasoglu, A. (2003). Capability-based distributed layout approach for virtual manufacturing cells. International Journal of Production Research, 41(11), 2597–2618.
  • Baykasogu, A. & Gindy, N. (2000). MOCACEF 1.0: Capability based approach to form part-machine groups for cellular manufacturing applications. International Journal of Production Research, 38(5), 1133-111161.
  • Bhandwale, A. & Kesavadas, T. (2008). A methodology to incorporate product mix variations in cellular manufacturing. Journal of Intelligent Manufacturing, 19, 71–85.
  • Braglia, M., Gabbrielli, R. & Micon, D. (2001). Material Handling Device Selection in Cellular Manufacturing. Journal of Multi-Criteria Decision Analysis, 10, 303–315.
  • Burbidge, J. L. (1992). Change to group technology: Process organization is obsolete. International Journal of Production Research, (30)5, 1209-1219.
  • Chakravorty, S. S., & Hales, D. N. (2008). The evolution of manufacturing cells: An action research study. European Journal of Operational Research, 188, 153–168.
  • Chan, F. T. S., Lau, K. W., Chan, L. Y.& Lo, V. H. Y., (2008). Cell formation problem with consideration of both intracellular and intercellular movements. International Journal of Production Research, 46(10), 2589-2620.
  • Chandrasekharan, M. P. & Rajagopalan, R. (1989). GROUPABILITY: an analysis of the properties of binary data matrices for group technology. International Journal of Production Research, (27), 1035–1052.
  • Clegg, C. W., Wall, T. D., Pepper, K., Stride, C., Woods, D., Morrison D., Corder, J., Couchman, P., Badham, R., Kuenzler, C., Grote, G., Ide, W., Takahashi, M.& Kogi, K. (2002). An International Survey of the Use and Effectiveness of Modern Manufacturing Practices. Human Factors and Ergonomics in Manufacturing, 12 (2), 171–191.
  • Copuroglu, H. (2000). Total planning of parts, fixtures and tools for cellular manufacturing. Unpublished master’s thesis, Eskisehir Osmangazi University, Turkey.
  • Da Silveira, G. (1999). A methodology of implementation of cellular manufacturing. International Journal of Production Research, 37(2), 467-479.
  • Das, K., Lashkari R. S.& Sengupta, S. (2007). Machine reliability and preventive maintenance planning for cellular manufacturing systems. European Journal of Operational Research, 183, 162–180.
  • Dawson, P. (2005). Changing Manufacturing Practices: An Appraisal of the Processual Approach. Human Factors and Ergonomics in Manufacturing, 15 (4), 385–402.
  • Defersha, F. M. & Chen, M. (2006). A comprehensive mathematical model for the design of cellular manufacturing systems. International Journal of Production Economics , 103, 767–783.
  • Durmusoglu, M. B., Kulak, O., & Balci, H. H., (2003). Analysis and Evaluation of CM Practice in Turkey (in Turkish). Endustri Muhendisligi Dergisi, 14 (2), 2-20.
  • Heragu, S. S. (1994). Group technology and cellular manufacturing. Transactions on Systems, Man and Cybernetics, 24(2), 203-215.
  • Hu, G. H., Chen, Y. P. & Zhou, Z. D. & Fang, H. C. (2007). A genetic algorithm for the inter-cell layout and material handling system design. International Journal of Advanced Manufacturing Technology, 34, 1153–1163.
  • Irani, S. A. & Huang, H. (2006). Cascading flow lines and layout modules: Practical strategies for machine duplication in facility layouts. International Journal of Flexible Manufacturing Systems, 17, 119–149
  • Islier, A. A. (2000). Dynamic layout for dynamic production. Otomasyon, 11, 64–68.
  • Islier, A. A. (2005). Group technology by an ant system algorithm. International Journal of Production Research, 43 (5), 913-932.
  • Kamrani, A. K. & Parsei, H. R. (1992). A methodology for forming manufacturing cells using manufacturing and design attributes. Computers and Industrial Engineering, 23(1), 73-76.
  • Kao, Y. & Fu, S. C. (2006). An ant-based clustering algorithm for manufacturing cell design, International Journal of Advanced Manufacturing Technology, 28, 1182–1189.
  • Kizil, M., Ozbayrak, M. & Papadopoulou, T. C. (2006). Evaluation of dispatching rules for cellular manufacturing, International Journal of Advanced Manufacturing Technology, 28, 985-992.
  • Koufteros, X. & Marcoulide, G. A. (2006). Product development practices and performance: A structural equation modeling-based multi-group analysis. International Journal of Production Economics, 103, 286–307.
  • Kumar, A. (2004). Mass Customization: Metrics and Modularity. The International Journal of Flexible Manufacturing Systems, 16, 287–311.
  • Kumar, C. S. & Chandrasekharan, M.P., (1990). Grouping efficacy: a quantitative criterion for goodness of block diagonal forms of binary matrices in group technology. International Journal of Production Research, (28), 233–243.
  • Kumar, K. R. & Vannelli, A. (1987). Strategic subcontracting for efficient disaggregated manufacturing. International Journal of Production Research, 25(2), 1715-1728.
  • Kwok, M. (1992). Manufacturing System Design for the Industrial Engineer, Industrial Engineering, (93), 35-39.
  • Lei, D. & Wu, Z. (2006). Tabu search for multiple-criteria manufacturing cell design. International Journal of Advanced Manufacturing Technology, 28, 950-956.
  • Mahdavi, I. & Mahadevan, B. (2008). CLASS: An algorithm for cellular manufacturing system and layout design using sequence data. Robotics and Computer-Integrated Manufacturing, 24, 488–497.
  • Mahesh, O. & Srinivasan, G. (2006). Multi-objectives for incremental cell formation problem. Annals of Operations Research, 143, 157–170.
  • Manning, W. & Jensen, J. (2006). Evaluating the shop-wide performance effect of pooling synergy with analytical models. European Journal of Operational Research, 175, 1009–1020.
  • Mansour, S. A., Husseini, S. M. & Newman, S.T. (2000). A review of modern approaches to multi-criteria cell design. International Journal of Production Research, 38(5), 1201-1218.
  • Marsh, R. F., Shafer, S. M. & Meredith, J. R. (1999). A Comparison of Cellular Manufacturing Research Presumptions with Practice. International Journal of Production Research, 37(14), 3119-3138.
  • Maslow, A. H. (1943). A Theory of Human Motivation, Psychological Review, 50(4), 370-396.
  • Mehrabad, M. S. & Safaei, N. (2007). A new model of dynamic cell formation by a neural approach. International Journal of Advanced Manufacturing Technology, 33, 1001–1009.
  • Montreuil, B., Venkatadri, U. & Rardin, R. L., (1999). Fractal layout organization for job shop environments. International Journal of Production Research, 37, 501–521.
  • Murugan, M. & Selladurai, V. (2007). Optimization and implementation of cellular manufacturing system in a pump industry using three cell formation algorithms. International Journal of Advanced Manufacturing Technology, 35, 135–149.
  • Nomden, G. & van der Zee, D. J. (2008). Virtual cellular manufacturing: Configuring routing flexibility. International Journal of Production Economics, 112, 439–451.
  • Nomden, G., Slomp, J. &·Suresh, N. C. (2006). Virtual manufacturing cells: A taxonomy of past research and identification of future research issues. International Journal of Flexible Manufacturing Systems, 17, 71–92.
  • Ozcelik, F. & Islier, A. A. (2003).Novel approach to multi-channel manufacturing system design. International Journal of Production Research, 41(12), 2711-2126.
  • Ozcelik, F. (2001). Layout planning for multi channel manufacturing, Unpublished master’s thesis, Eskisehir Osmangazi University, Turkey.
  • Park, K. S. & Han, S. W. (2002). Performance Obstacles in Cellular Manufacturing Implementation—Empirical Investigation. Human Factors and Ergonomics in Manufacturing, 12 (1), 17–29.
  • Pattanaik, L. N. & Sharma, B. P. (2009). Implementing lean manufacturing with cellular layout: a case study. International Journal of Advanced Manufacturing Technology, 42, 772–779.
  • Pattanaik, L. N., Jain, P. K. & Mehta, N. K. (2007). Cell formation in the presence of reconfigurable machines. International Journal of Advanced Manufacturing Technology, 34, 335–345.
  • Reisman; A., Kumar; A., Motwani; J. & Cheng, C. H. (1997). Cellular manufacturing: A statistical review of the literature (1965-1995). Operations Research, 4 (4), 508-521.
  • Saad, S. M. & Lassila, A. M. (2004). Layout design in fractal organizations. International Journal of Production Research, 42 (17), 3529–3550.
  • Safaei, N., Mehrabad, M. S. & Babakhani, M. (2007). Designing cellular manufacturing systems under dynamic and uncertain conditions. Journal of Intelligent Manufacturing, 18, 383–399.
  • Sarker, B. R. & Yu, J. (2007). A quadra-directional decomposition heuristic for a two-dimensional, non-equidistant machine-cell location problem. Computers & Operations Research, 34, 107–151.
  • Satoglu, S. I., Durmusoglu M. B. & Dogan, I. (2006). Evaluation of the conversion from central storage to decentralized storages in cellular manufacturing environments using activity-based costing. International Journal of Production Economics, 103, 616–632.
  • Siemiatkowski, M. & Przybylski, W. (2007). Modelling and simulation analysis of process alternatives in the cellular manufacturing of axially symmetric parts. International Journal of Advanced Manufacturing Technology, 32, 516–530.
  • Singh, N. (1993). Design of cellular manufacturing systems: An invited review. European Journal of Operations Research, 69(3), 284-291.
  • Spiliopoulos, K. & Sofianopoulou, S. (2008). An efficient ant colony optimization system for the manufacturing cells formation problem. International Journal of Advanced Manufacturing Technology, 36, 589–597.
  • Sujono, S. & Lashkar, R. S. (2007). A multi-objective model of operation allocation and material handling system selection in FMS design. International Journal of Production Economics, 105, 116–133.
  • Tsai, C. C. & Lee, C.Y. (2006). Optimization of manufacturing cell formation with a multi-functional mathematical programming model. International Journal of Advanced Manufacturing Technology, 30, 309–318.
  • Venkatadri,U., Rardin,R. L. & Montreuil, B., (1997) A design methodology for fractal layout organization. IEE Transactions, 29, 911–924.
  • Wemmerlov, U. & Hyer, N. L. (1989). Cellular manufacturing in the U.S. industry: A survey of users. International Journal of Production Research, 27(9), 1511–1530.
  • Wemmerlov, U. & Johnson, D. J. (2000). Empirical findings on manufacturing cell design. International Journal of Production Research, 38(3), 481–507.
  • Won, Y. & Currie, K. R. (2006). An Effective P-median Model Considering Production Factors in Machine Cell Part Family Formation. Journal of Manufacturing Systems, 25(1), 58-64.
  • Wu, X., Chu, C. H., Wang, Y. & Yan, W. (2007). A genetic algorithm for cellular manufacturing design and layout. European Journal of Operational Research, 181, 156–167.
  • Yang, M. S., Hung, W. L. & Cheng, F. C. (2006). Mixed-variable fuzzy clustering approach to part family and machine cell formation for GT applications. International Journal of Production Economics, 103, 185–198.
  • Yin, Y. & Yasuda, K. (2006). Similarity coefficient methods applied to the cell formation problem: A taxonomy and review. International Journal of Production Economics, 101, 329–352.
  • Yin, Y. (2009). The economic cell number. International Journal of Advanced Manufacturing Technology, 44, 625–630.

Volume 3, Issue 2, 2015

2015.03.02.OR.02

alphanumeric journal

Volume 3, Issue 2, 2015

Pages 13-26

Received: Sept. 3, 2015

Accepted: Oct. 10, 2015

Published: Dec. 31, 2015

Full Text [614.4 KB]

2015 İşlier, AA.

This is an Open Access article, licensed under Creative Commons Attribution-NonCommercial 4.0 International License.

Creative Commons Attribution licence

scan QR code to access this article from your mobile device


Contact Us

Faculty of Transportation and Logistics, Istanbul University
Beyazit Campus 34452 Fatih/Istanbul/TURKEY

Bahadır Fatih Yıldırım, Ph.D.
editor@alphanumericjournal.com
+ 90 (212) 440 00 00 - 13219

alphanumeric journal

alphanumeric journal has been publishing as "International Peer-Reviewed Journal" every six months since 2013. alphanumeric serves as a vehicle for researchers and practitioners in the field of quantitative methods, and is enabling a process of sharing in all fields related to the operations research, statistics, econometrics and management informations systems in order to enhance the quality on a globe scale.