Scheduling for Cellular Manufacturing
Alcatel-Lucent is a major player in the field of telecommunications. One of the products it offers to network operators is wireless infrastructure such as base stations. Such equipment is delivered in cabinets. These cabinets are packed with various pieces of electronics: filters, amplifiers, circuit packs, etc. The exact configuration of a cabinet is dependent upon the circumstances it is being placed in, and some 20 product groups can be distinguished. However, the variation in cabinets is large, even within one product group. For this reason, they are built to order.
In order to improve cost, yield and delivery performance, lean manufacturing concepts were applied to change the layout of the factory to one based on cells. These cells focus on improving manufacturing through standardised work, limited changeovers between product groups and better utilisation of test equipment. A key component in the implementation of these improvements is a system which schedules the cells to satisfy customer request dates in an efficient sequence.
This paper describes the transformation and the tool that was built to support the new method of operations. The implementation has achieved significant improvements in manufacturing interval, work in process inventory, first test yield, headcount, quality (i.e. fewer defects are found during the testing stage) and delivery performance. Although these benefits are mainly achieved because of the change to a cell layout, the scheduling tool is crucial in realising the full potential of it.
KeywordsProduct Group Assembly Line Test Engineer Delivery Performance Cellular Manufacture
Unable to display preview. Download preview PDF.
- 1.Bixby, R., Burda, R., Miller, D.: Short-interval detailed production scheduling in 300mm semiconductor manufacturing using mixed integer and constraint programming. In: The 17th Annual SEMI/IEEE Advanced Semiconductor Manufacturing Conference (ASMC 2006), pp. 148–154. IEEE Computer Society Press, Los Alamitos (2006)Google Scholar
- 2.Golany, B., Dar-El, E.M., Zeev, N.: Controlling shop floor operations in a multi- family, multi-cell manufacturing environment through constant work-in-process. IIE Transactions 31, 771–781 (1999)Google Scholar
- 3.Ilog: Ilog OPL Studio 3.7.1 help files (2005)Google Scholar
- 4.Bellone, J., Chamard, A., Fischler, A.: Constraint logic programming decision sup- port systems for planning and scheduling aircraft manufacturing at dassault aviation. In: Proceedings of the Third International Conference on the Practical Applications of Prolog, pp. 111–113 (1995)Google Scholar
- 5.Creed, P., Berry, S., Little, J., Goyal, S., Cokely, D.: Thermal test scheduling using constraint programming. In: Proceedings of the 12th IFAC Symposium on Information Control Problems in Manufacturing (2006)Google Scholar
- 6.Love, D.: International Encyclopedia of Business and Management. In: The Design of Manufacturing Systems, vol. 4, pp. 3154–3174. Thompson Business Press (1996)Google Scholar
- 8.Le Pape, C.: An application of constraint programming to a specific production scheduling problem. Belgian Journal of Operations Research, Statistics and Computer Science (1995)Google Scholar