Dynamic Cellular Remanufacturing System (DCRS) Design (original) (raw)
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CIRP Journal of Manufacturing Science and Technology, 2017
While "sustainability" in the manufacturing sector is becoming a pivotal issue, one should consequently expect a growing research interest in design problems in "Sustainable Manufacturing Systems" (SMSs). When a product ceases to be of any further use to the customer in it is current condition, it is relinquished. Accordingly, there is a need for a product recovery options in a sustainable environment. Recycling and remanufacturing are the most two advanced product recovery options. An efficient recycling and remanufacturing network leads to an efficient design of Sustainable Manufacturing enterprise. This article presents a simultaneous investigation of Reconfigurable Cellular Manufacturing Systems and Hybrid Manufacturing-Remanufacturing Systems (HMRSs), and proposes an integrated approach in design optimization, analysis, and process planning aspects as an attempt to address to a large number of design issues for Sustainable Manufacturing Systems. The options of remanufacturing, recycling, and disposing are introduced. A mixed integer linear programming (MILP) model, which considers a classical cell formation problem in Cellular Manufacturing Systems (CMSs), bridged with a production planning problem, in Hybrid Manufacturing-Remanufacturing Systems, while addressing to "reconfiguration" issues for the CMS for different production periods, has been developed. A numerical example is presented to illustrate the proposed model.
2013
Due to increasing international competition, shorter product life-cycles, variable demand, diverse customer needs and customized products, manufacturers are forced from mass production to the production of a large product mix. Traditional manufacturing systems, such as job shops and flow lines, cannot provide such requirements efficiently coupled with flexibility to handle these changes. Cellular Manufacturing (CM) is an alternate manufacturing system combining the high throughput rates of line layouts with the flexibility offered by functional layouts (job shops). The benefits include reduced set-up times, material handling, in-process inventory, better product quality, and faster response time. The benefits of CM can only be achieved by sufficiently incorporating the real-life structural and operational features of a manufacturing plant when creating the cellular layout. This research presents integrated CM models, with an extensive coverage of important manufacturing structural a...
Dynamic cellular manufacturing systems design—a comprehensive model
International Journal of Advanced Manufacturing Technology, 2011
This paper addresses the dynamic cell formation problem (DCF). In dynamic environment, the product demand and mix changes in each period of a multiperiod planning horizon. It causes need of reconfiguration of cells to respond to the product demand and mix change in each period. This paper proposes a mixed-integer nonlinear programming model to design the dynamic cellular manufacturing systems (DCMSs) under dynamic environment. The proposed model, to the best of the author’s knowledge, is the most comprehensive model to date with more integrated approach to the DCMSs. The proposed DCMS model integrates concurrently the important manufacturing attributes in existing models in a single model such as machine breakdown effect in terms of machine repair cost effect and production time loss cost effect to incorporate reliability modeling; production planning in terms of part inventory holding, part internal production cost, and part outsourcing; process batch size; transfer batch size for intracell travel; transfer batch size for intercell travel; lot splitting; alternative process plan, and routing and sequence of operation; multiple copies of identical copies; machine capacity, cutting tooling requirements, work load balancing, and machine in different cells constraint; machine in same cell constraint; and machine procurements and multiple period dynamic cell reconfiguration. Further, the objective of the proposed model is to minimize the sum of various costs such as intracell movement costs; intercell movement costs and machine procurement costs; setup cost; cutting tool consumption costs; machine operation costs; production planning-related costs such as internal part production cost, part holding costs, and subcontracting costs; system reconfiguration costs; and machine breakdown repair cost, production time loss cost due to machine breakdown, machine maintenance overheads, etc. ,in an integrated manner. Nonlinear terms of objective functions are transformed into linear terms to make mixed-integer linear programming model. The proposed model has been demonstrated with several problems, and results have been presented accordingly.
Flexible Design of Cellular Manufacturing System for Dynamic Production Requirements
Manufacturing industries are under intense pressure from the increasingly competitive global marketplace. Shorter product life cycle, time-to-market and diverse customer needs have challenged manufacturers to improve the efficiency and productivity of their production activities. Manufacturing systems should be able to adjust or respond quickly to adopt necessary changes in product design and product demand without major investment. Traditional manufacturing systems, such as, job shops and flow lines are not capable of satisfying such requirements. Although a cellular manufacturing system (CMS) provides great benefits, the design of CMS is complex for real life problems. Existing design methods employ simplifying assumptions, which often deteriorate the validity of the models used for obtaining solutions. In this paper, a method of flexible CMS has been discussed and a case study is presented in a reputed gear manufacturing industry, which converted functional layout into CMS. There was reduction of Rs 1 05 234.84 in the total cost per week after converting functional layout into CMS. The CMS worked successfully with two different machines-parts combinations. Keywords : Cellular manufacturing system; Simulated annealing; Cell configuration; Cost reduction
Dynamic Cellular Manufacturing System and sustainable manufacturing
In previous decades, manufacturers faced a lot of challenges because of globalization and high competition in markets. These problems arise from shortening product life cycle, rapid variation in demand of products, and also rapid changes in manufcaturing technologies. Nowadays most manufacturing companies expend considerable attention for improving flexibility and responsiveness in order to overcome these kinds of problems and also meet customer's needs. By considering the trend toward the shorter product life cycle, the manufacturing environment is towards manufacturing a wide variety of parts in small batches [1]. One of the major techniques which are applied for improving manufacturing competitiveness is Cellular Manufacturing System (CMS). CMS is type of manufacturing system which tries to combine flexibility of job shop and also productivity of flow shop. In addition, Dynamic cellular manufacturing system which considers different time periods for the manufacturing system becomes an important topic and attracts a lot of attention to itself. Therefore, this paper made attempt to have a brief review on this issue and focused on all published paper on this subject. Although, this topic gains a lot of attention to itself during these years, none of previous researchers focused on reviewing the literature of that which can be helpful and useful for other researchers who intend to do the research on this topic. Therefore, this paper is the first study which has focused and reviewed the literature of dynamic cellular manufacturing system.
Dynamic Cellular Manufacturing System: A Review
Cell-formation procedures ignore any changes in demand over time caused by product redesign and uncertainties due to volume variation, part mix variation and resource unreliability till today. Nowadays for business environment product life cycles are short, demand volumes and product mix can vary frequently, in this context Cellular Manufacturing System (CMS) configuration for a period might not be an optimal or even not to be feasible for the next periods or next process. Thus now for economical production, the manufacturing cell design will sustain with only Dynamic Cellular Manufacturing System (DCMS). DCMS model gives the best multiple routings, reconfiguration and production planning, etc., for various time periods and also DCMS leads the best optimal time as well as best optimal cost to the material movements (or) transfer in assembly (or) production lines, which provides the flexibility to the cellular manufacturing system to respond for any variations in part mix demand or volume variation.
A PRACTICAL METHODOLOGY FOR CELLULAR MANUFACTURING SYSTEMS DESIGN -AN INDUSTRIAL STUDY
The product oriented organization of manufacturing systems based on group technology cells, typical of lean production, is a very effective organization to timely meet customer requirements and take full advantage of production resources. Frequently it has been pointed out that studies on cellular manufacturing systems tend to be theoretical and addressing only a few of the relevant practical issues. In this paper, a comprehensive industrial study for reconfiguring a production system into a product oriented manufacturing system, based on GT cells, carried out in a company manufacturing leather goods, it is reported. This study take into account all important and necessary issues, for system reconfiguration, namely capacity requirements, actual and expected future demand, existing resources and required and available physical space. A practical methodological approach for part family formation, machines allocation to cells and cellular layout planning are put forward. Procedures for dealing with exceptional elements towards minimizing intercellular workflow and for streamlining material flow within cells and across cells are also described and implemented. In this particular study separating kits of raw parts at the beginning of parts processing and joined them together again at the end of processing was a requirement that needed to be addressed and made reliable to avoid severe mistakes when assembling parts into final products. This requirement was an additional motivation for organizing production into cells leading to a much more reliable kitting operation greatly due to the streamlined and synchronized work flow of parts achieved. The study proposes reorganizing the system into three autonomous GT cells and a gateway work centre, with resources practically reduced to the minimum required based on product demand. The study compares the initial configuration solution with the proposed one showing advantages of the proposed solution under a few evaluation issues, namely in relation to work flow organization, movement of materials and reliability of the parts kitting for final assembly.
Dynamic Cellular Manufacturing System Design for Automated Factories
In this paper, an integrated mathematical model of the multi-period cell formation in a dynamic cellular manufacturing system (DCMS) is proposed with the aim of getting the optimal cost f o r i t. In DCMS, the formed cells in the current period may not be optimal for the next period, so the reconfiguration of the cell is needed, thus we have a tendency to use DCMS. The paper examines the influence of the trade-off between assorted manufacturing costs on the reconfiguration of the cells in Cellular Manufacturing System (CMS) under a lively environment and the proposed model is implemented to a wide range of numerical examples.
A Literature Survey on Various Factors in Dynamic Cellular Manufacturing System
Cellular manufacturing system deals with grouping of machines and parts into machine cells and part families with their compatibility. Reduction in part life cycle and variation in product mix and demand creates dynamic condition in the manufacturing systems. In previous work manufacturing companies has faces a lot of problems in meeting the customer requirement in dynamic conditions. Cellular Manufacturing System is a type of manufacturing system which tries to create a flexibility of job type and also productivity in shop floor. Now a day's Dynamic cellular manufacturing system becomes the emerging topic and attracts of lot of attention at different times intervals. This paper gives the brief review about the work which was focused on all published paper on this subject.