METHODOLOGY FOR CONVERTING A FUNCTIONAL MANUFACTURING SYSTEM INTO A CELLULAR MANUFACTURING SYSTEM

This paper reports the development of a suitable model and a solution algorithm as well as the findings of a comprehensive analysis performed to convert an existing functional manufacturing (FM) system in the parts manufacturing plant (PMP) of Freightliner Corporation, a major truck manufacturing company in Portland, OR, USA, into a cellular manufacturing (CM) system. Past experiences of the PMP management show parts which have one or more operations scheduled to be performed on punching machines requiring significantly higher material handling costs than those that did not. As a result, only a subset of 810 different parts that have one or more operations needed to be performed on punching machines and 62 different machine types are included in the analysis. A planning horizon of one year is used, and the objective function of the model is formulated as minimization of total moves evaluated as a weighted sum of inter- and intracell moves exhibited by parts, taking into consideration the part routings. All of the operational constraints are included in the model, and a heuristic solution algorithm is proposed to determine the best part machine assignments to manufacturing cells. Computer programs, written in MICROSOFT-QUICKC, are implemented on a COMPAQ-386 microcomputer. Based on the results of the study, a suitable solution is recommended to the PMP management.