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Cellular manufacturing is the organisation of manufacturing equipment based on the requirements of the product or component. Transition to cellular manufacturing generally requires reorganisation of existing equipment. It is likely that the existing equipment alone is not suitable for a cellular layout. During the cell planning and design phase equipment investment analysis is important to identify equipment needs. Transition from job shop production to cellular production is detailed. Cell formation and cell evaluation techniques are provided to assist in equipment procurement decisions. In particular, a structured procedure and analytical tools are given to evaluate fully the cellular system to identify appropriate equipment and methods. A case example is provided to explain the procedure.

To compare the performance of a new hybrid manufacturing system (HMS) with a conventional cellular manufacturing system (CMS). The hybrid system is a combination of the cellular manufacturing and job shop.

A hypothetical manufacturing facility with eight machines and 20 parts is used as a case. Simulation models are developed for two manufacturing systems. A multi‐factor comparison is carried out to test the performance of the systems under different scenarios.

It was found that group scheduling rules (GSR) and the manufacturing system design factors have significant impact on the performance of the system. In particular, the hybrid system shows its best performance when the MSSPT GSR is applied, whereas the cellular system is superior when DDSI is implemented. The results also demonstrate that, by adding non‐family parts to the production schedule of the HMS, significant benefits in the performance measures can be attained.

The conclusion cannot be generalized, as the result is dependent upon the input data and the size of the problem.

The application may be limited to certain industry sectors. Further studies may be needed to identify the appropriate industry.

While the majority of the literature focuses on either a job shop or a pure CMS, this paper has a distinctive approach that allows the combined use of both systems. This could be a useful transitional approach from one system to the other.

Without reliance on results obtained from applying a cell formation method, this paper aims to describe a simple quantitative approach to testing whether an underlying pattern of relationships exists between machines of a given system, such that the machines may be rearranged into manufacturing cells. It also aims to support the approach by an index for measuring the clustering tendency.

The eigenvalues of the similarity coefficient matrix and Kaiser's rule are used to: detect the number of clusters existing in the part‐machine matrix, and derive an index for predicting the goodness of the best possible obtainable cell formation.

The results of applying the proposed approach and the clustering tendency index to problems of different sizes taken from the literature have proven that both the approach and the clustering tendency index are powerful in performing the feasibility assessment and in predicting the right number of manufacturing cell to be formed.

This study is of considerable value to practitioners because it provides them with a powerful yet very easy to apply approach for assessing the feasibility of adopting cellular manufacturing in early stages of design. Another characteristic of this approach is the possibility of using it as a decision support tool for practitioners who opt to use a cell formation method which requires specifying the number of cells in advance. Moreover, the approach does not require any special software package, since it can be easily performed using several available software packages such as MATLAB and Mathematica.

A methodology for evaluating the adaptability of a system to cellular manufacturing has been proposed in a previous study. However, the methodology used is complex and uses a certain degree of subjectivity. In contrast, the proposed approach is simple and completely quantitative. Furthermore, a new index for measuring the clustering tendency is presented.

Contrasts functional layouts and cellular layouts with regard to the effects of set‐up time reduction and lot size on flow time and through‐put. The structural environment for the functional analysis is an efficient functional system with a staged sequence of four machine centers with unidirectional flow and no backtracking. The structural environment for the cellular analysis is a partitioned cell consisting of one machine from each of the four machine types with unidirectional flow and no backtracking. Simulation models produce robust results for eight lot size levels and one (functional model) and seven (cellular model) set‐up time reduction levels. The results contrast the effectiveness of the two manufacturing approaches under differing input conditions. Shows that the choice between the functional structure and the cellular structure significantly affects through‐put at lot sizes up to 55, while for lot sizes of 60 and above there is no significant effect. The study also confirms previous results regarding the effect of manufacturing structure choice on flow time.

Proposes a virtual cellular manufacturing approach to implementing cellular manufacturing systems that combines the set‐up efficiency typically obtained by traditional cellular manufacturing or group technology systems with the flexibility of a job shop. Unlike traditional cellular systems in which the shop is physically designed as a series of cells, cells are formed within a shop utilizing a process layout using scheduling mechanisms. The result is the formation of cells that are temporary and logical (virtual) in nature, allowing them to be more responsive to changes in demand patterns. Simulation runs comparing this approach to production using traditional cellular and job shop approaches indicate that this new approach yields significantly better shop performance over a range of operating conditions.

Based on detailed analysis of seven case studies, involving consideration of approximately 300 parameters and face to face interviews with senior managers, identifies key characteristics which should be taken into account during the selection and effective implementation of different types of manufacturing control systems in individual manufacturing environments. These key characteristics help identify the need for particular functions of manufacturing control systems, as well as the impact on effective implementation and operation. They are grouped under the headings of complexity, uncertainty and flexibility. Concludes with a discussion of a structured approach which may be used to take account of key characteristics during the selection of a manufacturing control system.

Simulation experiment was employed to investigate the schemes for coordinating JIT practices to promote performance upgrade in a job shop environment with the pull system.

The four related essential JIT practices (job shop JIT practices) investigated include: cellular manufacturing (CM), operations overlapping (OPOVR), reduction of set‐up/processing time variability (variability reduction) and set‐up time reduction (STR).

Experiment findings suggest that coordination of CM and STR should be given the priority. While the extent of STR effected by CM substantially influences the efficacy of adopting a cellular layout, the choice of adopting a functional layout (FL) is more likely to be affected by the STR resulted from improvement of set‐up operations (set‐up improvement). Variability reduction tends to be more effective for a cellular layout. For a cellular layout without OPOVR, the effectiveness of reducing set‐up time variability is prominent and almost impervious to the extent of set‐up improvement. For a FL, the effect of variability reduction is minor; reduction of set‐up time variability is effective in this case only for a set‐up to processing time ratio of 20 or larger. The findings of this study do not justify the implementation of OPOVR in the shop environment, even with the support of the other three job shop JIT practices.

This study is notable in integrating STR into the job shop JIT practices to achieve overall performance improvement. In addition, the resulting strategies for variability reduction are essential for adapting the pull system to job shop manufacturing. Therefore, the findings of this study form systematic guidelines enabling exercise of the job shop JIT practices coherently to promote reform of job shop manufacturing.

This paper is aimed at comparing cellular manufacturing with focused cellular manufacturing. We define focused cellular manufacturing as a layout scheme that groups components by end‐items and forms cells of machines to fabricate and assemble end‐items. It is not classified as a cellular manufacturing layout since it does not attempt to take advantage of process similarities. It also is not classified as a flow shop since there are no machines dedicated to individual operations and the machines are not arranged in a series. In addition, this research includes batching and assemble times in its criteria which few researchers in this area have done. The results indicate that the focused cellular manufacturing scheme has a batching advantage. This advantage out‐weighed the set‐up time reduction advantage of the cellular manufacturing scheme for average end‐item completion times and average work‐in‐process inventory levels. The cellular manufacturing scheme overcame the batching advantage only when there were small batch sizes or large set‐up time magnitudes.

Using the weighted similarity coefficient (WSC) technique in the design of manufacturing facilities provides the system designer with a suitable method for the creation of efficient manufacturing cells. The formation of such well designed machine cells will then hopefully ensure that the achievable cost reduction benefits, in terms of lower operational costs incurred via the transfer of components between machines, are obtained by companies that wish to use cellular manufacturing in their approach to production operations. The aim of this paper is to outline and evaluate the application of a particular WSC equation to the formulation and design of cellular manufacturing systems.

By using a pragmatic approach, the paper chronicles the design and development of a particular weighted similarity coefficient as a means of defining a possibly useful methodology for cell design in manufacturing systems. The technique outlined is subsequently evaluated for its generic nature, applicability and effectiveness via the use of previously published synthetic production data and a comparison with the results of several alternative approaches.

The development of the proposed weighted similarity coefficient to manufacturing cellular design is outlined in the paper and the appropriateness of the technique is subsequently evaluated in order that the benefits obtainable by its use to a host organisation are highlighted. In addition, the results show how the approach can lead to useful improvements in cellular manufacturing performance if adopted by manufacturing system designers and implemented in their designs.

The design, development and application of the WSC proposed and its use in manufacturing cellular design provides a simple yet highly effective approach to achieving useful improvements in production system performance through improved work‐part transfer efficiency and associated cost savings. The paper offers practising manufacturing managers and engineers a technique whereby manufacturing cell productive efficiency and output can be improved whilst at the same time achieving a reduction in operational costs.

The paper focuses on the proposed WSC technique which contributes to the existing knowledge base on production cell design and may also provide impetus, guidance, support and encouragement for designers to achieve improved output performance and reduced costs in their manufacturing system designs.

As the manufacturing activities in today's industries are getting more and more complex, it is required for the manufacturing firm to have a good shop floor production scheduling to plan and schedule their production orders. An accurate scheduling is essential to any manufacturing firm in order to be competitive in global market. The paper aims to discuss these issues.

Two types of shop floors, job shop and cellular layout, were developed by using WITNESS simulation package. Consequently, the performance of forward scheduling and backward scheduling in both job shop and cellular layout was compared using simulation method, and the results were analyzed by using analysis of variance (ANOVA). Through analysis, the best scheduling approach and layout to be used by manufacturing firm in order to achieve the make-to-order (MTO) production and inventory strategy were reported.

The results from simulation show that backward scheduling in job shop layout has the lowest average throughput time, lowest lateness, and highest labour productivity than forward scheduling. While in cellular layout, forward scheduling has the lowest average throughput time, lowest lateness, and highest labour productivity than backward scheduling in all conditions. It shows that the performance of scheduling approach is different in each production layout.

Suitable scheduling approach is needed in manufacturing industry as to maximize production rate and optimize machine and process capability. This paper presents an empirical study about the assembly process of radio cassette player of one manufacturing industry in order to investigate the impact of variety of orders and different number of two workers on the performance of production scheduling approach. Forward scheduling and backward scheduling are used to schedule the production orders.