A hybrid genetic-variable neighborhood search algorithm for the cell formation problem based on grouping efficacy

Cell formation problem attempts to group machines and part families in dedicated manufacturing cells such that the number of voids and exceptional elements in cells are minimized. In this paper, we presented a linear fractional programming model with the objective of maximizing the grouping efficacy while the number of cells is unknown. To show the effectiveness of the proposed model, two test problems were applied. Then, to solve the model for real-sized applications, a hybrid meta-heuristic algorithm in which genetic algorithm and variable neighborhood search are combined. Using the grouping efficacy measure, we have also compared the performance of the proposed algorithm on a set of 35 test problems from the literature. The results show that the proposed GA-VNS method outperforms the state-of-the-art algorithms.     

A bacteria foraging algorithm based cell formation considering operation time

The cellular manufacturing system (CMS) is considered as an efficient production strategy for batch type production. The CMS relies on the principle of grouping machines into machine cells and grouping machine parts into part families based on pertinent similarity measures. The bacteria foraging algorithm (BFA) is a new in development computation technique extracted from the social foraging behavior of Escherichia coli (E. coli) bacteria. Ever since Kevin M. Passino invented the BFA, one of the main challenges has been employment of the algorithm to problem areas other than those for which the algorithm was proposed. This research work inquires the first applications of this emerging novel optimization algorithm to the cell formation (CF) problem. In addition, a newly developed BFA-based optimization algorithm for CF is discussed. In this paper, an attempt is made to solve the cell formation problem meanwhile taking into consideration number of voids in cells and a number of exceptional elements based on operational time of the parts required for processing in the machines. The BFA is suggested to create machine cells and part families. The performance of the proposed algorithm is compared with a number of algorithms that are most commonly used and reported in the corresponding scientific literature such as similarity coefficients methods (SCM), rank order clustering (ROC), ZODIAC, GRAFICS, MST, GATSP, GP, K-harmonic clustering (KHM), K-means clustering, C-link clustering, modified ART1, GA (genetic algorithm), evolutionary algorithm (EA), and simulated annealing (SA) using defined performance measures known as modified grouping efficiency and grouping efficacy. The results lie in favor of better performance of the proposed algorithm.     

A hybrid grouping genetic algorithm for the cell formation problem

The machine-part cell formation problem consists of constructing a set of machine cells and their corresponding product families with the objective of minimizing the inter-cell movement of the products while maximizing machine utilization. This paper presents a hybrid grouping genetic algorithm for the cell formation problem that combines a local search with a standard grouping genetic algorithm to form machine-part cells. Computational results using the grouping efficacy measure for a set of cell formation problems from the literature are presented. The hybrid grouping genetic algorithm is shown to outperform the standard grouping genetic algorithm by exceeding the solution quality on all test problems and by reducing the variability among the solutions found. The algorithm developed performs well on all test problems, exceeding or matching the solution quality of the results presented in previous literature for most problems.     

An adaptive hybrid genetic algorithm for the three-matching problem

This paper presents a hybrid genetic algorithm (GA) with an adaptive application of genetic operators for solving the 3-matching problem (3MP), an NP-complete graph problem. In the 3MP, we search for the partition of a point set into minimal total cost triplets, where the cost of a triplet is the Euclidean length of the minimal spanning tree of the three points. The problem is a special case of grouping and facility location problems. One common problem with GA applied to hard combinatorial optimization, like the 3MP, is to incorporate problem-dependent local search operators into the GA efficiently in order to find high-quality solutions. Small instances of the problem can be solved exactly, but for large problems, we use local optimization. We introduce several general heuristic crossover and local hill-climbing operators, and apply adaptation to choose among them. Our GA combines these operators to form an effective problem solver. It is hybridized as it incorporates local search heuristics, and it is adaptive as the individual recombination/improvement operators are fired according to their online performance. Test results show that this approach gives approximately the same or even slightly better results than our previous, fine tuned GA without adaptation. It is better than a grouping GA for the partitioning considered. The adaptive combination of operators eliminates a large set of parameters, making the method more robust, and it presents a convenient way to build a hybrid problem solver     

A new genetic algorithm for the machine/part grouping problem involving processing times and lot sizes

This paper reports a new genetic algorithm (GA) for solving a general machine/part grouping (GMPG) problem. In the GMPG problem, processing times, lot sizes and machine capacities are all explicitly considered. To evaluate the solution quality of this type of grouping problems, a generalized grouping efficacy index is used as the performance measure and fitness function of the proposed genetic algorithm. The algorithm has been applied to solving several well-cited problems with randomly assigned processing times to all the operations. To examine the effects of the four major factors, namely parent selection, population size, mutation rate, and crossover points, a large grouping problem with 50 machines and 150 parts has been generated. A multi-factor (3⁴) experimental analysis has been carried out based on 324 GA solutions. The multi-factor ANOVA test results clearly indicate that all the four factors have a significant effect on the grouping output. It is also shown that the interactions between most of the four factors are significant and hence their cross effects on the solution should be also considered in solving GMPG problems.     

A novel approach to determine cell formation,intracellular machine layout and cell layout in the CMS problem based on TOPSIS method

This paper deals with the cellular manufacturing system (CMS) that is based on group technology (GT) concepts. CMS is defined as identifying the similar parts that are processed on the same machines and then grouping them as a cell. The most proposed models for solving CMS problems are focused on cell formation and intracellular machine layout problem while cell layout is considered in few papers. In this paper we apply the multiple attribute decision making (MADM) concept and propose a two-stage method that leads to determine cell formation, intracellular machine layout and cell layout as three basic steps in the design of CMS. In this method, an initial solution is obtained from technique for order preference by similarity to the ideal solution (TOPSIS) and then this solution is improved. The results of the proposed method are compared with well-known approaches that are introduced in literature. These comparisons show that the proposed method offers good solutions for the CMS problem. The computational results are also reported.     

An Electromagnetism-like algorithm for cell formation and layout problem

Implementation of cellular manufacturing systems (CMS) is thriving among manufacturing companies due to many advantages that are attained by applying this system. In this study CMS formation and layout problems are considered. An Electromagnetism like (EM-like) algorithm is developed to solve the mentioned problems. In addition the required modifications to make EM-like algorithm applicable in these problems are mentioned. A heuristic approach is developed as a local search method to improve the quality of solution of EM-like. Beside in order to examine its performance, it is compared with two other methods. The performance of EM-like algorithm with proposed heuristic and GA are compared and it is demonstrated that implementing EM-like algorithm in this problem can improve the results significantly in comparison with GA. In addition some statistical tests are conducted to find the best performance of EM-like algorithm and GA due to their parameters. The convergence diagrams are plotted for two problems to compare the convergence process of the algorithms. For small size problems the performances of the algorithms are compared with an exact algorithm (Branch & Bound).     

The cell formation problem in cellular manufacturing systems—A sequential modelling approach

A sequential modelling approach to the cell formation problem in cellular manufacturing systems is presented in this paper. First, the machines are grouped into cells based on their similarity in parts processing; next the parts are allocated to appropriate machine groups based on the processing requirements. The machine grouping and the parts allocation problems are modelled as 0–1 integer programs. The application of the models is illustrated using a numerical example.     

A new mathematical model for integrating all incidence matrices in multi-dimensional cellular manufacturing system

In the past several years, many studies have been carried out on cellular manufacturing based on a two-dimensional machine–part incidence matrix. Since workers have important role in doing jobs on machines, assignment of workers to cells becomes a crucial factor for fully utilization of cellular manufacturing systems. In this paper, an attempt is made to solve cell formation problem and minimize the number of voids and exceptional elements in a three dimensional (cubic) machine–part–worker incidence matrix. The proposed mathematical model captures the capability of workers in doing different jobs. To demonstrate the effectiveness of the proposed model, the solution of some test problems is compared with the literature method.     

Clustering algorithm for solving group technology problem with multiple process routings

Cell formation is an important problem in the design of a cellular manufacturing system. Most of the cell formation methods in the literature assume that each part has a single process plan. However, there may be many alternative process plans for making a specific part, specially when the part is complex. Considering part multiple process routings in the formation of machine-part families in addition to other production data is more realistic and can produce more independent manufacturing cells with less intercellular moves between them. A new comprehensive similarity coefficient that incorporates multiple process routings in addition to operations sequence, production volumes, duplicate machines, and machines capacity is developed. Also, a clustering algorithm for machine cell formation is proposed. The algorithm uses the developed similarity coefficient to calculate the similarity between machine groups. The developed similarity coefficient showed more sensitivity to the intercellular moves and produced better machine grouping.     

A mathematical programming model for manufacturing cell formation to develop multiple configurations

This paper presents and analyses a mathematical model for the design of manufacturing cells which considers two conflicting objectives such as the heterogeneity of cells and the intercell moves. A genetic algorithm (GA) based solution methodology is developed for the model which is also solved using an optimization package. The model is suitable for getting multiple potential solutions in a structured way for the cell formation problem by making a trade-off between the two objectives, instead of reaching at a single negotiating solution. This model provides the decision maker the flexibility of choosing a suitable cell design from different alternatives by considering the practical constraints. A part assignment heuristic is also developed by which part-families can be identified and is integrated with the GA based solution procedure. A comparison of the proposed method is made with other seven methods using 36 problems from the literature. Grouping efficacy is the basis for comparison and it is found to give reasonably good results.     

An efficient tabu search algorithm to the cell formation problem with alternative routings and machine reliability considerations

Cell formation is the first step in the design of cellular manufacturing systems. In this study, an efficient tabu search algorithm based on a similarity coefficient is proposed to solve the cell formation problem with alternative process routings and machine reliability considerations. In the proposed algorithm, good initial solutions are first generated and later on improved by a tabu search algorithm combining the mutation operator and an effective neighborhood solution searching mechanism. Computational experiences from test problems show that the proposed approach is extremely effective and efficient. When compared with the mathematical programming approach which took three hours to solve problems, the proposed algorithm is able to produce optimal solutions in less than 2 s.     

Machine-component grouping using genetic algorithms

One major problem in cellular manufacturing is the grouping of component parts with similar processing requirements into part families, and machines into manufacturing cells to facilitate the manufacturing of specific part families assigned to them. The objective is to minimize the total inter-cell and intra-cell movements of parts during the manufacturing process. In this paper, a mathematical model is presented to describe the characteristics of such a problem. An approach based on the concept of genetic algorithms is developed to determine the optimal machine-component groupings. Illustrative examples are used to demonstrate the efficiency of the proposed approach. Indeed, the results obtained show that the proposed genetic approach is a simple and efficient means for solving the machine-component grouping problem.     

Development of bacteria foraging optimization algorithm for cell formation in cellular manufacturing system considering cell load variations

The cellular manufacturing system (CMS) is considered as an efficient production strategy for batch type production. The CMS relies on the principle of grouping machines into machine cells and grouping machine parts into part families on the basis of pertinent similarity measures. The bacteria foraging optimization (BFO) algorithm is a modern evolutionary computation technique derived from the social foraging behavior of Escherichia coli bacteria. Ever since Kevin M. Passino invented the BFO, one of the main challenges has been the employment of the algorithm to problem areas other than those of which the algorithm was proposed. This paper investigates the first applications of this emerging novel optimization algorithm to the cell formation (CF) problem. In addition, for this purpose matrix-based bacteria foraging optimization algorithm traced constraints handling (MBATCH) is developed. In this paper, an attempt is made to solve the cell formation problem while considering cell load variations and a number of exceptional elements. The BFO algorithm is used to create machine cells and part families. The performance of the proposed algorithm is compared with a number of algorithms that are most commonly used and reported in the corresponding scientific literature such as K-means clustering, the C-link clustering and genetic algorithm using a well-known performance measure that combined cell load variations and a number of exceptional elements. The results lie in favor of better performance of the proposed algorithm.     

A meta-heuristic algorithm to solve quadratic assignment formulations of cell formation problems without presetting number of cells

The purpose of cellular manufacturing (CM) is to find part-families and machine cells which form self-sufficient units of production with a certain amount of autonomy that result in easier control (Kusiak, 1987, 1990). One of the most important steps in CM is to optimally identify cells from a given part-machine incidence matrix. Several formulations of various complexities are proposed in the literature to deal with this problem. One of the mostly known formulations for CM is the quadratic assignment formulation (Kusiak and Chow, 1988). The problem with the quadratic assignment based formulation is the difficulty of its solution due to its combinatorial nature. The formulation is also known as NP-hard (Kusiak and Chow, 1988). In this paper a novel simulated annealing based meta-heuristic algorithm is developed to solve quadratic assignment formulations of the manufacturing cell formation problems. In the paper a novel solution representation scheme is developed. Using the proposed solution representation scheme, feasible neighborhoods can be generated easily. Moreover, the proposed algorithm has the ability to self determine the optimal number of cell during the search process. A test problem is solved to present working of the proposed algorithm.     

A cell formation problem considering machine utilization and alternative process routes by scatter search

Cell formation (CF) is the first step in the design of cellular manufacturing systems (CMSs), which has been recognized as an effective way to enhance the productivity in a factory. There is a set of criteria on which to judge route of product, machine grouping and part family simultaneously in terms of the effective utilization of these cells. In this study, we consider four objectives simultaneously: (1) Minimizing the total fixed and variable cost including costs of purchasing, operation, and maintenance; (2) minimizing cost of intercellular movements; (3) maximizing the utilization of machines in the system; and (4) minimizing deviations among the levels of the cell utilization (i.e., balancing the workload between cells). In this paper, these objectives are first weighted by their relative importance and then a new mathematical model is presented. To solve this model, a scatter search (SS) algorithm is proposed to select a process plan for each part with the minimum cost along with forming the part family and machine grouping simultaneously. The performance of the proposed SS is compared with the Lingo 8.0 software. A number of test problems are carried out to verify the good ability of the proposed SS in terms of the solution quality and computational time. The computational results reveal that the SS finds promising results, especially in the case of large-sized problems.     

Solving a multi-floor layout design model of a dynamic cellular manufacturing system by an efficient genetic algorithm

This paper presents a mixed-integer programming model for a multi-floor layout design of cellular manufacturing systems (CMSs) in a dynamic environment. A novel aspect of this model is to concurrently determine the cell formation (CF) and group layout (GL) as the interrelated decisions involved in the design of a CMS in order to achieve an optimal (or near-optimal) design solution for a multi-floor factory in a multi-period planning horizon. Other design aspects are to design a multi-floor layout to form cells in different floors, a multi-rows layout of equal area facilities in each cell, flexible reconfigurations of cells during successive periods, distance-based material handling cost, and machine depot keeping idle machines. This model incorporates with an extensive coverage of important manufacturing features used in the design of CMSs. The objective is to minimize the total costs of intra-cell, inter-cell, and inter-floor material handling, purchasing machines, machine processing, machine overhead, and machine relocation. Two numerical examples are solved by the CPLEX software to verify the performance of the presented model and illustrate the model features. Since this model belongs to NP-hard class, an efficient genetic algorithm (GA) with a matrix-based chromosome structure is proposed to derive near-optimal solutions. To verify its computational efficiency in comparison to the CPLEX software, several test problems with different sizes and settings are implemented. The efficiency of the proposed GA in terms of the objective function value and computational time is proved by the obtained results.     

Optimum loading of machines in a flexible manufacturing system using a mixed-integer linear mathematical programming model and genetic algorithm

Machine loading problem in a flexible manufacturing system (FMS) encompasses various types of flexibility aspects pertaining to part selection and operation assignments. The evolution of flexible manufacturing systems offers great potential for increasing flexibility by ensuring both cost-effectiveness and customized manufacturing at the same time. This paper proposes a linear mathematical programming model with both continuous and zero-one variables for job selection and operation allocation problems in an FMS to maximize profitability and utilization of system. The proposed model assigns operations to different machines considering capacity of machines, batch-sizes, processing time of operations, machine costs, tool requirements, and capacity of tool magazine. A genetic algorithm (GA) is then proposed to solve the formulated problem. Performance of the proposed GA is evaluated based on some benchmark problems adopted from the literature. A statistical test is conducted which implies that the proposed algorithm is robust in finding near-optimal solutions. Comparison of the results with those published in the literature indicates supremacy of the solutions obtained by the proposed algorithm for attempted model.     

Multi-objective Genetic Algorithms for grouping problems

Linear Linkage Encoding (LLE) is a convenient representational scheme for Genetic Algorithms (GAs). LLE can be used when a GA is applied to a grouping problem and this representation does not suffer from the redundancy problem that exists in classical encoding schemes. LLE has been mainly used in data clustering. One-point crossover has been utilized in these applications. In fact, the standard recombination operators are not suitable to be used with LLE. These operators can easily disturb the building blocks and cannot fully exploit the power of the representation. In this study, a new crossover operator is introduced for LLE. The operator which is named as group-crossover is tested on the data clustering problem and a very significant performance increase is obtained compared to classical one-point and uniform crossover operations. Graph coloring is the second domain where the proposed framework is tested. This is a challenging combinatorial optimization problem for search methods and no significant success has been obtained on the problem with pure GA. The experimental results denote that GAs powered with LLE can provide satisfactory outcomes in this domain, too.