Title: Hybrid cellular manufacturing system design with cellularisation ratio: an integrated mixed integer nonlinear programming and discrete event simulation approach

Authors: Gokhan Egilmez; Bulent Erenay; Gürsel A. Süer

Addresses: Department of Mechanical and Industrial Engineering, University of New Haven, West Haven CT 06516, USA ' Sidhu School of Business, Wilkes University, Wilkes Barre, PA, USA ' Department of Industrial and Systems Engineering, Ohio University, Athens, OH, USA

Abstract: This study investigates hybrid cellular manufacturing system design where products with highly similar process routes are formed as manufacturing cells, and products with dissimilar routes are produced in a process layout. A cell similarity threshold, cellularisation ratio (C-ratio), is proposed for product assignment to cells and process layout, and integrated into a mathematical modelling-based cell formation approach. The cell formation phase is carried out with the proposed mathematical model. Several case problems are tested, and selected cases are also studied with a newly developed simulation model where manufacturing system performance is also evaluated along with the proposed hybrid cellular manufacturing design alternatives. Results indicated that considering a C-ratio during cell formation can provide higher cell similarity thus better cell formation. The increase in the coverage levels resulted in higher number of cells formed. The proposed approach can be significantly beneficial for manufacturing design decisions where product mix and process complexity are high, and for a hybrid layout that consists of cellular plus process layouts could be implemented.

Keywords: cellularisation ratio; C-ratio; stochastic cellular system; mixed integer nonlinear programming; discrete event simulation; hybrid layout; cell formation; process layout.

DOI: 10.1504/IJSOM.2019.097036

International Journal of Services and Operations Management, 2019 Vol.32 No.1, pp.1 - 24

Received: 01 Apr 2016
Accepted: 22 Dec 2016
Published online: 17 Dec 2018 *

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