A multi-objective mathematical model for cellular manufacturing systems design with probabilistic demand and machine reliability analysis

This paper presents a dynamic multi-objective mixed integer mathematical model for cell formation problem with probabilistic demand and machine reliability analysis, where the total system costs, machine underutilization cost, and maximum system failure rate over the planning time periods are to be minimized simultaneously. The total system cost objective function calculates machine operating, internal part production, intercellular material handling, and subcontracting costs. Since in this type of problems, objectives are in conflict with each other, so finding an ideal solution (a solution that satisfies all objectives simultaneously) is not possible. Therefore, this study uses the augmented ε-constraint method (to solve small size problems) and a nondominated sorting genetic algorithm (NSGAII) (to solve large size problems) to find the Pareto optimal frontier that decision makers can select her/his preferred solution. Numerical examples will be solved to demonstrate the efficiency of the proposed algorithm.

[1]  Eckart Zitzler,et al.  Evolutionary algorithms for multiobjective optimization: methods and applications , 1999 .

[2]  Masoud Rabbani,et al.  A multi-objective scatter search for a dynamic cell formation problem , 2009, Comput. Oper. Res..

[3]  Javad Rezaeian,et al.  A multi-objective integrated cellular manufacturing systems design with dynamic system reconfiguration , 2011 .

[4]  Zhi-ming Wu,et al.  A genetic algorithm for manufacturing cell formation with multiple routes and multiple objectives , 2000 .

[5]  Michael Masin,et al.  An Efficiency Frontier Approach for the Design of Cellular Manufacturing Systems in a Lumpy Demand Environment , 2001, Eur. J. Oper. Res..

[6]  Iraj Mahdavi,et al.  A genetic algorithm for solving a multi-floor layout design model of a cellular manufacturing system with alternative process routings and flexible configuration , 2013 .

[7]  Farzad Mahmoodi,et al.  Scheduling unbalanced cellular manufacturing systems with lot splitting , 2000 .

[8]  Mingyuan Chen A model for integrated production planning in cellular manufacturing systems , 2001 .

[9]  Charles E Ebeling,et al.  An Introduction to Reliability and Maintainability Engineering , 1996 .

[10]  F. Robert Jacobs,et al.  A simulation comparison of group technology with traditional job shop manufacturing , 1986 .

[11]  R. S. Lashkari,et al.  Machine reliability and preventive maintenance planning for cellular manufacturing systems , 2007, Eur. J. Oper. Res..

[12]  K. Yasuda *,et al.  A grouping genetic algorithm for the multi-objective cell formation problem , 2005 .

[13]  Reza Tavakkoli-Moghaddam,et al.  A simulated annealing method for solving a new mathematical model of a multi-criteria cell formation problem with capital constraints , 2009, Adv. Eng. Softw..

[14]  Chien-Wei Wu,et al.  An efficient approach to determine cell formation, cell layout and intracellular machine sequence in cellular manufacturing systems , 2013, Comput. Ind. Eng..

[15]  Dong Cao,et al.  Coordinating production planning in cellular manufacturing environment using Tabu search , 2004, Comput. Ind. Eng..

[16]  Masoud Rabbani,et al.  A NEW APPROACH TOWARDS INTEGRATED CELL FORMATION AND INVENTORY LOT SIZING IN AN UNRELIABLE CELLULAR MANUFACTURING SYSTEM , 2011 .

[17]  Maghsud Solimanpur,et al.  Solving cell formation problem in cellular manufacturing using ant-colony-based optimization , 2010 .

[18]  Ghorbanali Moslemipour,et al.  A review of intelligent approaches for designing dynamic and robust layouts in flexible manufacturing systems , 2012 .

[19]  S. Selcuk Erenguc,et al.  A mathematical approach for integrating the cell design and production planning decisions , 2000 .

[20]  M. Saidi-Mehrabad,et al.  A new model of dynamic cell formation by a neural approach , 2007 .

[21]  S. Ross A First Course in Probability , 1977 .

[22]  Jannes Slomp,et al.  A multi-objective procedure for labour assignments and grouping in capacitated cell formation problems , 2001 .

[23]  Li Pheng Khoo,et al.  Multiple-objective optimization of machine cell layout using genetic algorithms , 2003, Int. J. Comput. Integr. Manuf..

[24]  Jia Zhixin,et al.  Probability distribution of machining center failures , 1995 .

[25]  Brett A. Peters,et al.  A comparison of setup strategies for printed circuit board assembly , 1998 .

[26]  Sang-Jae Song,et al.  Integrated autonomous cellular manufacturing - a new concept for the 21st century , 2001, Int. J. Manuf. Technol. Manag..

[27]  K. Das A comparative study of exponential distribution vs Weibull distribution in machine reliability analysis in a CMS design , 2008, Comput. Ind. Eng..

[28]  Angelo Oreste Andrisano,et al.  A review on artificial intelligence applications to the optimal design of dedicated and reconfigurable manufacturing systems , 2014, The International Journal of Advanced Manufacturing Technology.

[29]  Jamal Arkat,et al.  Modelling the effects of machine breakdowns in the generalized cell formation problem , 2008 .

[30]  D. Cao,et al.  A robust cell formation approach for varying product demands , 2005 .

[31]  Maghsud Solimanpur,et al.  Designing a mathematical model for dynamic cellular manufacturing systems considering production planning and worker assignment , 2010, Comput. Math. Appl..

[32]  Tolga Bektas,et al.  Integrated cellular manufacturing systems design with production planning and dynamic system reconfiguration , 2009, Eur. J. Oper. Res..

[33]  Deming Lei,et al.  Tabu search for multiple-criteria manufacturing cell design , 2006 .

[34]  Hamid Seifoddini,et al.  The effect of reliability consideration on the application of quality index , 2001 .

[35]  Henri Pierreval,et al.  Manufacturing cell design with flexible routings capability in presence of unreliable machines , 1999 .

[36]  Wilson L. Price,et al.  Hybrid genetic approach for solving large-scale capacitated cell formation problems with multiple routings , 2006, Eur. J. Oper. Res..

[37]  Mingyuan Chen,et al.  Machine cell formation using a mathematical model and a genetic-algorithm-based heuristic , 2006 .

[38]  Nancy Lea Hyer,et al.  Cellular manufacturing in the U.S. industry: a survey of users , 1989 .

[39]  S. H. Zegordi,et al.  A genetic algorithm for multiple objective dealing with exceptional elements in cellular manufacturing , 2003 .

[40]  P. K. Jain,et al.  Dynamic cellular manufacturing systems design—a comprehensive model , 2011 .

[41]  Yazhou Jia,et al.  Distribution of time between failures of machining center based on type I censored data , 2003, Reliab. Eng. Syst. Saf..

[42]  V. Madhusudanan Pillai,et al.  A mathematical programming model for manufacturing cell formation to develop multiple configurations , 2014 .

[43]  George Mavrotas,et al.  Effective implementation of the epsilon-constraint method in Multi-Objective Mathematical Programming problems , 2009, Appl. Math. Comput..

[44]  P. Siarry,et al.  Multiobjective Optimization: Principles and Case Studies , 2004 .

[45]  Kalyanmoy Deb,et al.  A fast and elitist multiobjective genetic algorithm: NSGA-II , 2002, IEEE Trans. Evol. Comput..