Study On Cell Formation And Scheduling Problem For Cellular Manufacturing

Cellular manufacturing (CM) is a production system, in which parts requiring a similar production process are grouped in distinct manufacturing cells. It incorporates the flexibility of job shops and the high production rate of flow shop lines. The major advantages of cellular manufacturing systems(CMS) have been reported in the literature, such as reduction in throughput time, work-in-process inventories, and material handling costs; better quality and production control; enhancement in flexibility; and the like.Based on analyzing the research status quo of cellular manufacturing in a deep going way, this thesis detailedly study the crucial problems on implementation and operation of cellular manufacturing systems, which is cell formation and scheduling problem. According to "20-80"phenomenon in the pareto principle, a large number of common parts is formed static manufacturing cell under multi-product and small lot-size production,and the others is formed virtual manufacturing cell technology. For static cell formation problem,this paper considers the actual manufacture information, the factor analysis of multivariate statistical method is applied to form manufacturing cell effectively and quickly.For dynamic reconfiguration problem of manufacturing cells, according to the dynamic changes of production tasks, a dynamic reconfiguration general framework of manufacturing cell for make-to-order manufacturing is proposed and a dynamic reconfiguration algorithm of manufacturing cell is developed. Consider the practical factors in the production process, the corresponding mathematic machine selection model aiming to minimize processing cost and maxmize capacity factor of production processes simultaneously was constructed and ant colony algorithm is design to solving this model. For cell scheduling problem,cell scheduling framework based on theory of constraints(TOC) is constructed. Considering the bottleneck capacity constraints, a heuristic cell scheduling apporach based on theory of constraints is proposed for the objective of minimization weighted sum of the punishment cost of tardy deliveries and inventory holding cost.This paper also provided an application of the cell formaiton and scheduling into Zhenjiang Diesel Engine Factory. First, the basic situation of the plant is introduced, and the status and problems about production management is analyzed.Then, by collecting data of the production system, the method about cell formaiton and scheduling proposed in this paper is successfully applied to the workshop 1of this company. Finally, the feasibility and effectiveness of the approach was proved by witness simulation.