An interactive program for machine grouping and layout

Abstract

A number of companies have reaped the benefits offered by cellular manufacturing systems (CMSs) (Wemmerlov and Hyer, 1986). Typical benefits include: set-up time reduction, improved machine utilization, an increase in production rate and employee morale, a decrease in labor costs and traffic congestion and better control of the manufacturing system. Cellular manufacturing (CM) involves grouping of machines based on the parts they manufacture. The grouping of machines and parts in a CMS is briefly explained here by considering a simple example. Figure 9.1 shows four part routings. The first row indicates that part 1 is routed through machines A, C and E in succession. Figure 9.2 shows the arrangement of the machines referred to in Fig. 9.1 in a job shop environment. Figure 9.3 shows the arrangement of the same machines in ‘cells’. Notice that each cell is dedicated to production of a set of parts. The main idea behind grouping ‘like’ machines into cells is to minimize intercellular part movement. After grouping is done, the next logical step is to develop a layout for the cells and machines within each cell so that both intercellular and intracellular material handling cost is minimized. This step, however, is often ignored.