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A new approach towards integrated cell formation and inventory lot sizing in an unreliable cellular manufacturing system
Authors:K Rafiee  M Rabbani  H Rafiei  A Rahimi-Vahed
Institution:1. Department of Industrial Engineering, University of Houston, TX 77204-4008, USA;2. Department of Industrial Engineering, Faculty of Engineering, University of Tehran, P.O. Box 11155-4563, Tehran, Iran;3. Départment d’informatique et de recherche opérationnelle, Université de Montréal, Montreal, Quebec, Canada
Abstract:This paper presents a comprehensive mathematical model for integrated cell formation and inventory lot sizing problem. The proposed model seeks to minimize cell formation costs as well as the costs associated with production, while dynamic conditions, alternative routings, machine capacity limitation, operations sequences, cell size constraints, process deterioration, and machine breakdowns are also taken into account. The total cost consists of machine procurement, cell reconfiguration, preventive and corrective repairs, material handling (intra-cell and inter-cell), machine operation, part subcontracting, finished and unfinished parts inventory cost, and defective parts replacement costs. With respect to the multiple products, multiple process plans for each product and multiple routing alternatives for each process plan which are assumed in the proposed model, the model is combinatorial. Moreover, unreliability conditions are considered, because moving from “in-control” state to “out-of-control” state (process deterioration) and machine breakdowns make the model more practical and applicable. To conquer the breakdowns, preventive and corrective actions are adopted. Finally, a Particle Swarm Optimization (PSO)-based meta-heuristic is developed to overcome NP-completeness of the proposed model.
Keywords:Unreliable cellular manufacturing system  Dynamic system reconfiguration  Inventory lot sizing  Particle Swarm Optimization  Process deterioration  Machine breakdown
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