Amelioration of Capacity Constraints in Manufacturing Systems Using Alternate Production Sequence
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Abstract
Today’s market is in a constant flux of demand changes. Due to this the product demand and the product mix continuously change from one time-period to the next. For a company to be profitable and competitive, it has to ensure that all of its resources are optimally utilized. These resources include facility layout, material handling, and production system. Previous research has shown that the system state has to be identified prior to increasing capacity to mitigate the constraint. As the demand and product mix change, a facility layout that was efficient can soon become inefficient or the cost of production and material handling increase. This research evaluates usage of alternate part sequence as a means to eliminate or reduce production system constraints. It focuses on reducing machine usage when the selected process sequence leads to production capacity constraints.
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Published
August 4, 2017
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References
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Ameli, M. S. J., Arkat, J. & Barzinpour, F. (2008). Modelling the effects of machine breakdowns in the generalized cell formation problem. International Journal of Advanced Manufacturing Technology, 39, 838-850.
Azadivar, F., & Wang, J. J., (2000). Facility layout optimization and genetic algorithms. International Journal of Production Research, 38, 17, 4369-4383.
Balakrishnan, J., and Cheng, C. H. (2000). Genetic search and the dynamic layout problem. Computers and Operations Research, 27, 587-593.
Baykasoglu, A., and Gindy, N. N. Z. (2001). A simulated annealing algorithm for dynamic layout problem. Computers and Operations Research, 28, 1403-1426.
Benjaafar, S., and Sheikhzadeh, M. (2000). Design of flexible plant layouts. IIE Transactions, 32, 309-322.
Benjaafar, S., Heraghu, S. S. and S.A. Irani, (2002) “Next Generation Factory Layouts: Research challenges and recent progress,” Interfaces, Vol. 32(6), 58-76.
Conway, D. G., and Venkataramanan, M. A. (1994). Genetic search and the dynamic facility layout problem. Computers and Operations Research, 21, 8, 955-960.
Dhuttargoan, Krishnan, and Shah (2017), An Integrated Approach for the Analysis of Manufacturing System States, , Industrial and Systems Engineering Review 5(1), pp. 59-70.
Diallo, M., Pierreval, H. & Quilliot, A. (2001). Manufacturing cells design with flexible routing capability in the presence of unreliable machines. International Journal of production Economics, 74, 175-182.
Elleuch, M., Bacha, H. B., Masmoudi, F. & Maalej, A. Y. (2008). Analysis of cellular manufacturing systems in the presence of machine breakdowns – Effects of intercellular transfer. Journal of Manufacturing Technology Management, 19(2), 235-252.
Jabalameli, M. S., Arkat, J. & Sakri, M. S. (2008). Applying metaheuristics in the generalized cell formation problem considering machine reliability. Journal of the Chinese Institute of Industrial Engineers, 25(4), 261-274.
Jeon, G., Broering, M., Leep, H. R., Parasaei, H. R. & Wong, J. P. (1998). Part family formation based on a new similarity coefficient which considers alternative routes during machine failure. Computers & Industrial Engineering, 35(3-4), 479-482.
Jeon, G., Leep, H. R. & Parsaei, H. R. (1998). A cellular manufacturing system based on new similarity coefficient which considers alternative routes during machine failure. Computers & Industrial Engineering, 34(1), 21-36.
Kochhar, J. S., and Heragu, S. S. (1999). Facility layout design in a changing environment. International Journal of Production Research, 37, 11, 2429-2446.
Kouvelis, P., and Kiran, A. S. (1991). Single and Multiple period layout models for automated manufacturing systems. European Journal of Operational Research, 52, 300-314.
Krishnan, K.K., Cheraghi, S.H. and Nayak, C., (2006), “Dynamic from-between chart: a new tool for solving dynamic facility layout problems,” International Journal of Industrial and Systems Engineering, Vol. 1(½), pp. 182–200.
Krishnan, K.K., Jithavech, I., and Liao, H. (2009). Mitigation of Risk in Facility Layout Design for Single and Multi-Period Problems. International Journal of Production Research, 47, 21(1), 5911 – 5940.
Meller, R., and Gau, K.Y., (1996), “The facility layout problem: recent and emerging trends and perspectives,” Journal of Manufacturing Systems, Vol. 15, No. 5, pp. 351 – 366.
Shah, Krishnan, and Dhuttargoan (2015). Dynamic facility planning under production and material handling capacity constraints, submitted for review, Journal of Journal of Supply Chain and Operations Management, Vol. 13, #.1, 2015, pp. 78-107.
Tompkins, J.A., White, J.A.,Bozer, Y.A., & Tanchoco, J.M.A. (2010). Facilities Planning. Hoboken, NJ: John Wiley & Sons.
Urban, T. L. (1993). A Heuristic for the dynamic facility layout problem. IIE Transactions, 25, 4, 57-63.
Yang, T., and Peters, B. A. (1998). Flexible machine layout design for dynamic and uncertain production environments. European Journal of Operational Research, 108, 49-64.
Ameli, M. S. J., Arkat, J. & Barzinpour, F. (2008). Modelling the effects of machine breakdowns in the generalized cell formation problem. International Journal of Advanced Manufacturing Technology, 39, 838-850.
Azadivar, F., & Wang, J. J., (2000). Facility layout optimization and genetic algorithms. International Journal of Production Research, 38, 17, 4369-4383.
Balakrishnan, J., and Cheng, C. H. (2000). Genetic search and the dynamic layout problem. Computers and Operations Research, 27, 587-593.
Baykasoglu, A., and Gindy, N. N. Z. (2001). A simulated annealing algorithm for dynamic layout problem. Computers and Operations Research, 28, 1403-1426.
Benjaafar, S., and Sheikhzadeh, M. (2000). Design of flexible plant layouts. IIE Transactions, 32, 309-322.
Benjaafar, S., Heraghu, S. S. and S.A. Irani, (2002) “Next Generation Factory Layouts: Research challenges and recent progress,” Interfaces, Vol. 32(6), 58-76.
Conway, D. G., and Venkataramanan, M. A. (1994). Genetic search and the dynamic facility layout problem. Computers and Operations Research, 21, 8, 955-960.
Dhuttargoan, Krishnan, and Shah (2017), An Integrated Approach for the Analysis of Manufacturing System States, , Industrial and Systems Engineering Review 5(1), pp. 59-70.
Diallo, M., Pierreval, H. & Quilliot, A. (2001). Manufacturing cells design with flexible routing capability in the presence of unreliable machines. International Journal of production Economics, 74, 175-182.
Elleuch, M., Bacha, H. B., Masmoudi, F. & Maalej, A. Y. (2008). Analysis of cellular manufacturing systems in the presence of machine breakdowns – Effects of intercellular transfer. Journal of Manufacturing Technology Management, 19(2), 235-252.
Jabalameli, M. S., Arkat, J. & Sakri, M. S. (2008). Applying metaheuristics in the generalized cell formation problem considering machine reliability. Journal of the Chinese Institute of Industrial Engineers, 25(4), 261-274.
Jeon, G., Broering, M., Leep, H. R., Parasaei, H. R. & Wong, J. P. (1998). Part family formation based on a new similarity coefficient which considers alternative routes during machine failure. Computers & Industrial Engineering, 35(3-4), 479-482.
Jeon, G., Leep, H. R. & Parsaei, H. R. (1998). A cellular manufacturing system based on new similarity coefficient which considers alternative routes during machine failure. Computers & Industrial Engineering, 34(1), 21-36.
Kochhar, J. S., and Heragu, S. S. (1999). Facility layout design in a changing environment. International Journal of Production Research, 37, 11, 2429-2446.
Kouvelis, P., and Kiran, A. S. (1991). Single and Multiple period layout models for automated manufacturing systems. European Journal of Operational Research, 52, 300-314.
Krishnan, K.K., Cheraghi, S.H. and Nayak, C., (2006), “Dynamic from-between chart: a new tool for solving dynamic facility layout problems,” International Journal of Industrial and Systems Engineering, Vol. 1(½), pp. 182–200.
Krishnan, K.K., Jithavech, I., and Liao, H. (2009). Mitigation of Risk in Facility Layout Design for Single and Multi-Period Problems. International Journal of Production Research, 47, 21(1), 5911 – 5940.
Meller, R., and Gau, K.Y., (1996), “The facility layout problem: recent and emerging trends and perspectives,” Journal of Manufacturing Systems, Vol. 15, No. 5, pp. 351 – 366.
Shah, Krishnan, and Dhuttargoan (2015). Dynamic facility planning under production and material handling capacity constraints, submitted for review, Journal of Journal of Supply Chain and Operations Management, Vol. 13, #.1, 2015, pp. 78-107.
Tompkins, J.A., White, J.A.,Bozer, Y.A., & Tanchoco, J.M.A. (2010). Facilities Planning. Hoboken, NJ: John Wiley & Sons.
Urban, T. L. (1993). A Heuristic for the dynamic facility layout problem. IIE Transactions, 25, 4, 57-63.
Yang, T., and Peters, B. A. (1998). Flexible machine layout design for dynamic and uncertain production environments. European Journal of Operational Research, 108, 49-64.
How to Cite
Amelioration of Capacity Constraints in Manufacturing Systems Using Alternate Production Sequence. (2017). Industrial and Systems Engineering Review, 5(1), 73-92. https://doi.org/10.37266/ISER.2017v5i1.pp73-92
How to Cite
Amelioration of Capacity Constraints in Manufacturing Systems Using Alternate Production Sequence. (2017). Industrial and Systems Engineering Review, 5(1), 73-92. https://doi.org/10.37266/ISER.2017v5i1.pp73-92
