A robust cellular manufacturing system design for dynamic part population using a genetic algorithm

As changing conditions prevail in the manufacturing environment, the design of cellular manufacturing systems, which involves the formation of part families and machine cells, is difficult. This is due to the fact that the machines need to be relocated as per the requirements if adaptive designs are used. This paper presents a new approach (robust design) for forming part families and machine cells, which can handle all the changes in demands and product mixes without any relocations. This method suggests fixed machine cells for the dynamic nature of the production environment by considering a multi-period forecast of product mix and demand. A genetic algorithm based solution procedure is adopted to solve the problem. The results thus obtained were compared with the adaptive design proposed by Wicks and Reasor (1999 Wicks, EM and Reasor, RJ. 1999. Designing cellular manufacturing systems with dynamic part populations. IIE Trans., 31: 11–20. [Taylor &; Francis Online], [Web of Science ®] , [Google Scholar]). It is found that the robust design performs better than the adaptive design for the problems attempted.