Kuside
Q
Group Technology: Models
and Algorithms
8.1 INTRODUCTION
‘The basic idea of group technology (GT) is to decompose a manufacturing
system into subsystems, Introduction of GT in manufacturing bas the following
advantages:
* + Reduced product
geduced wou
lead time (20-88%)
(20-20%)
tnd serap materials (15-75%)
and algorithms developed fac GT. There
1 the GT problem: .
Sec. 8.1 Introduction 207
Ny
C1" C830
Panto rousing Grouped pas
Figure 8.1 Pans gr
‘The classification 'method is used to group parts into part families based
on their design features. There are two vafations ofthe classification mathod:
+ Wisual method
* Coding method
+ 8.11 Visual Method
The visual method is a semisystematic procedure where parts are grouped
according tothe ties of the geometric shape, as shown in Figute 8.1,
‘where 10 parts have been grouped into 4 part families. Grouping parts using
this method.
the visual method is dependent on personal preferer
is applicable in cases where the number of parts is rathor
+ 81.2 Coding Method
In the coding method, parts ean be classified on the basis
features:
1. Geometric shape and complexity
2. Dimensions
3. Type of material
4. Shape of raw material
'S. Required accuracy of the finished part
Using a coding system, each partis assigned a numerical or alphat
code. Each digit of this code represents a feature of a part, The current 208 Group Technology: Models and Algorithms Chap. 8
wi | ie
sm
ow iP seem] [aT armas [me .
ay eo ea
SAF =
HET -
Figure 82 , monocode system and monocode
available coding systems differ with respect of the depth of coverage of the
receding five features. For example, a coding system may provide moce .
information on the shape and dimension of a part, whereas another may
emphasize more the accuracy of a part. There are three basic types of eoding
sy
+ Monacode
+ Polycode
+ Hybrid
‘An example of a monacode
are required. For a given pat, the lengt
thor compart othe snd atian ipa 108
8.2 CLUSTER ANALYSIS METHOD
sed on the object features,
such as biology (Event 1980), data ecogiton (eC
‘medicine (Klastorin 1982), pattern recogni
roduetion Flow analysis (Burbidge 1971; King 1980), task selec-
See.8.2 Cluster Anslysis Mothod 208
et
©O©
OO
Ungruse prs ant machine CGeouped prs matinee
Figure 8.3. "The phsial machine nyt
‘Tenda, and Shingu
‘automated systems (Kusiak 1985;
(Cheng and Fu 1985
‘The application
leads to:
41. Physical machine layout, or
2. Logical machine layout
‘Te ysl mache liyout eqs rarangemen
shop floor is altered as shown in
‘machines are grouped
is not altered (see Figuré
‘The logical grouping can be apy
is changing frequently so
clusters of machines end pas are wot vsblc. Clustering 0 Group Technology: Models and Al Chap.
ret
Unuoa prtandmacins rovpe ar ad racer
igure 8.4 The logial machine lsyout
transformation of an initial incidence matrix into
i ix into a more structured (poss
bly block diagonal) form. ae ety cae cri
Machine :
umber ep
Rearranging rows and columns in matrix (8.1) results in matrix (8.2):
Pr2
45
0
‘Two machine cel ), MCL
part families, PF-1 = {1,3) and PF-2 = (2,
are visible
ing of a binary incidence matrix may rest
categories of clusters:
the following two
“The two categories of clusters are oresented in matrices (8.2) and (8.3):
‘sec. 82 Cluster Analysis Method an
(3.3)
Mouix (83) cannot be separated into two disjoint clusters Because of
ar, which iso be machined in two cells, MC! tod MEE 2. Removing
ef S fom matic (8.3) results in the decompos
2} ané MC:
iy sep
ing tre actions can be taken:
can be machined in one machine cell and transferred to the other
chine cell by @ material handling cater
‘an be machined in a functional facility
“<- 3: Itean be subcontracted.
‘To solve te matrix formulation of the group teshnology problem, the
{allowing approaches have been developed:
«+ Similarity coefficient methods
+ Sortng-based algorithms
«+ Bond energy algorithm
+ Cos-based method
+ Cluster identification algorithm
1 Extended cluster identification algorithm
(x Similarity Coefficient Method:
‘methods ee discussed. The s
is based or
and j and is computed 95
coefficient sj measure
lows:
S sian
By aie 4p)
{: on =a, =!
0 otherwise
{°
1 otherwise
in = the number of pars
ee nee mmm! 22 Group Technology: Models and Algorithme Chap. 8
‘Sitar
iets for all possible pairs of machines are computed. Machine
ate generated based on a threshold value of the similarity coefficient
‘To illustrate the SLCA, consider matrix (8.3), The similarity coefii
44 ace computed next and depicted in Figure 8.5,
2
ss sy = 5 = O75
L
sy = 77028
‘Assuming the threshold value ofthe si
following machine cells are obtained from Figure 8.5:
MC = (1,2)
MC-2 = {3,4}
‘2 machine-part incidence matrix into submatrices, For example, machine 3 in
matrix (8.4) does not permit decomposition of that matrix into two machine
cells and two part families.
6.4)
trices is to purchase an additional copy of machine 3. The latter allows the
trix (8.4) into matrix (8.5),
‘See.8.2 Cluster Analysis Method m3
PRI PE-2
123456
ws)
‘Two machine cells, MC-1 =
corresponding pat families,
in matrix (8.5). Analogous to the defi
part can be defined,
“The use of the average linkage cl
the similarity coefficient
larity coefficient between
technology problem, Seifoddini and Wo
incidence matrix using @ binary machine code.
Jar movements (ICM) between two machine cells MC-/ and MC-jis computed
2s follows:
where
Note that
both machine ce
problem ean be
Tema = 5 HGous) <0 040404 Group Technology: Models and Algorithms Chap. 8
See, 8.2 Cluster Analysis Method 215
Is MC-1 and
Step 2. Sorting the decimal
smatic
42 __Sorting-Based Algorithms. The method of clustering based on sot
ing rows and columns of the machine-part incidence matrix has been studied
by many authors. King (1980) developed the rank order clustering (ROC)
algorithm. Laer SEER
Step
cach column produces the folowing
ROC Algorithm
Step 1. Foreach row of the machine-part in
weight and caleulate a decimal equi Machine
umber
tthe preceding steps until the position of each element in
| each row and column does not change.
|A weight for each row i snd column j are calculated as follows:
novi: Saat
Column j: SS ayae*
&
‘Step 1. Determine total number of 1s in each row and column in the
‘machine-part incidence matrix.
Step 2. Sort each row in increasing order corresponding to the total
umber of Is.
Inthe final matrix generated by the ROC algorithm, clusters are identified
visually. The ROC algorithm for matrix (8.1 rated in Example 8.1. 216 Group Tecnology: Models and Algorithms Chap.@ ——gge.82._ Cluster Anahsis Method a :
rnin decreasing order corresponding tothe
Pats [7=1 [st
preceding steps until the position of each elemem !
in each row and colucn doesnot change. mele lel %
ee al a) e
ae
& _ Bond-Energy
1972) developed an
algorithm (BEA). The BEA seeks to form a bl
ing the measure of effectiveness, which is def
Column 4 placed in the j + 1 post
») Part number
ES tase re unbe
‘The ME sisted next
Par
| surnber
1234 ‘The value of ME for this
ifr
Machine 2} 1 | Machine 2] 1 Slagle, Chang, and Heller (1975) developed a clustering algorithm based
‘on the BEA and the shortest spanning path (SPP) algorithm. Their concept
| Wh Api
| Step 1. Setj = I. Select one of the columns arbitrarily, mum 2a en!
| sere Cer ide chen ears a bt 0979 ai St
12 Bhat and Haupt algorithm permutes rows and columns
ix A-A as opposed to permuting rows and calculating matchings in
snatrix A in the McCormick et el. (1982) algorithm, One can note that an entry
Increase j by | and repeat the preceding steps until j = mij of matrix [mi] represents a distance between rows / and j of matrix A.
Step 3. When all the columns have been placed, repeat the procedure
for the rows; © — Cost-ased Method, Askin and Subramanian (1987) developed a %
Clustering algorithm that considers the following manufacturing costs
‘The BEA applied to matrix ( rated in Example 8.2.
1, Fixed and variable machining cost
2, Setup cost
epi. Set} = : 3. Production cycle inventory cost
bate 4, Work-in-process inventory cost
8. Material handling cost
SS
Example 8.2 218 Group Technology: Models and Algorithms Chap. 8
‘The algorithm consists of three stages. Inthe frst stage part are classified
using a coding system. In stage 2 an attempt is made to develop a feasible
‘grouping of parts based on the manufacturing costs. In stage 3 the actual layout
Of machine cells is analyzed
@,_Cluster Identification Algorithm. —_Kusiak and Chow (1987) appl
‘the concept presented in Ini (1968) to develop the cluster ide
algorithm, The cluster identification algorithm allows one to
tence of muwally separable clusters in a binary machine-part incidence mattix,
provided that they exist
CI Algorithm
read: matrix A at
For each entry of 1 crossed once by a vertical line ¥,
horizontal line hy
Step 4. Repeat steps 2 and
catties of Lin A”
machine
‘Step S. Transform the incidence matrix A‘) into'A'**” by removing
rows and columns corresponding to all the horizontal and ver-
steps 1 through 4.
0 (where O denotes a matrix with allelements
stop; otherwise set k= + and goto step |
(One ean notice thatthe cluster identification algorithm scans each element
of matrix A two times, Since there are mn elements in matrix A, its time
tion of the Cl algorithm for solving the group technology problem
rated in Example 8.3,
Example 8.3
Consider machine-pa
lence matrix (8.6).
Partnumber
12345678
‘Sec, 8.2 Cluster Analysis Method a9
Step 0. Set tertion number & = 1
Step 1. Row | of matrix (8.6) is selects and horizon
result of steps I and 2 are presented in mattis (8.7),
is drawn, The
Step 2. Thee vera lines v3.1, and vs are awn
12345678
an
‘Asa result of drawing these three vertical
‘are created in matix (8.7), ie,
through all the erossed-once
a8 shown in matrix 8.8).
12345678
ben benef
Step 3.
es)
Step 4. 220 Group Technology: Modele and Algorithme Chap. &
15.10)
8.10)
h 4 are performed on matrix (8.10),
ean
ae obtained
=(3,6} and PF-3 =(4,7} are obtained. The final
13)
PE2 PRS
2358 16 47
See. 82
(1976) algorithm more
Extended Cl Algt
(8.14
Using any of the
transformed into & more
Cluster Analysis Method 21
ey)
ire at
2] 11 1] Machine
3,1 1 | number
4 =
lodels and Algorithms = Chap. 8
possible grouping of machines and parts and also the efficiency of the Cl
algor
Extended CI Algorithm
Step 0. Set iteration number k = 1
Step 1. those machines (rows of matrix A'
‘orresporiding to these machines. In the absence of the
user's expertise any machine can be selected.
Step 2. For each column in A“ corresponding to the entry of | crossed
by any of the horizont
Step 3, For each row
by the verti drawn in step 2, draw a horizont
Based on the machines corresponding to all the horizontal
lines drawn in step 1 and step 3, a temporary machine cell,
MC'-k, is formed. If the production manager's expertise indi-
‘cates that some of the machines cannot be included in the tem-
porary machine cell MC'-k, erase the corresponding horizontal
lines in matrix A\*), Removal of these horizontal lines results in
machine cell MC-E.
Delete from matrix A parts (columns) that are to be manufac-
tured on at least one of the machines already included in MC-k.
st of parts to be manufactured in a
through each crossed-once entry of 1
in A which does not involve any other machines than those
included in MC-E.
Step 4. For all the crossed-twice entries of | in A, form a machine
cell MC-& and a part family PF-k.
Step 5. Transform the incidence matrix A\
to A“*!) by removing all
the rows and columns corresponding to the rows and columns
k and PE-k, respe
7
+) = 0 (where 0 denotes a matrix with all elements
equal to zero), stop: otherwise set k = k + | and go to step 1.
Step 6.
As one can see, computational complexity of the extended CI algorithm
is slightly higher than that of CI algorithm, mainly due to step 3. In cases
When the clustered matrix has block diagonal structure, computational time
f the extended cluster identification algorithm reduces to Ofmm);
equal ro the complexity of the cluster identification algorithm. The
extended cluster identification algorithm is illustrated in Example 8.4
Sec.8.2 Cluster Analysis Method 223
Example 8.4
Given the machine-part incidence matrix (8.16) determines mutually separable machine
cells and part families.
art number
1234567891011
pout 1 ]
ata 1 '
3 "| ntachine
Await db umber
3 staan
6}1. 4 rid
aL LE Pe
‘The user's expertise indicates that machines 1 and 4 should be
‘machine cell MC-1 and machines 3 and 5 should be included in machine
‘Some other expertise required is indicated later in the example,
Juded in
Step 0, Set iteration number = 1
Step 1. Since user's expertise indicates that machines 1 and 4 should be included
fon machine cell MC-1, two horizontal Tines /iy and hy are drawn, as
shown in matrix (8,
234567891011
ines, yy hg and fir, are drawn through rows 2, 6, und
‘erossed-once elements of 1 of matrix (8.18). The |
224
Group Technology: Models and Algorithms Chap. 8
1234567890N
hy 8.19)
Based on all the crossed twice el
porary machine cell Mi
ned. This temporary machine cell is evaluated by the’ prod.
anager. Assume that his or her expertise indicates that
‘machines 2 and 6 cannot be included in MC’-I. Since machines
2 and 6 are excluded, the horizontal lines hy and he
leads to the deletion of columns (parts)
‘of parts to be manufactured
facility. Since there are no more crossed
ine is drawn. As a res
8.20)
Sec. 8.2 Cluster Analysis Method 228
5 8 1011
Ws
* Machine cell MC-2 = {2,3,5,6) and
+ Part family PE-2 = (5,8, 10,14}
as shown in matrix (8.22)
PF-1 PR2
2367 5810 149
(8.23)
3
Mc2 $
6
‘The final result generated by the extended Cl
8.23).
Machine cells MC-1 and MC-2 and corresponding part fut
and PF-2 ate visible in matrix (8.23), The corresponding layout is i
in Figure 8.7.
‘The functional machining facility in Figure 8.7 sh
involve a set of 26 Group Technology: Models and Algorithms Chap. 8
1, Process plans for parts 1, 4, and 9 might be modified, so that each
of these parts could be machined in one of the two existing machine
cells MC-1 or MC-2.
2, Design of parts 1, 4, and 9 might be modified, so that the resulting
process plans could fit the existing machine cell MC-1 or MC-2.
3. Pars {, 4, and 9 might be manafictred in the two ex
User is not satisfied with the machine cells and part families
generated, he or she can repeat the entire computational process. Initiating the
extended Cl algorithm with another machine (or machines) in step 1 may result
in a different configuration of groups of machines and p:
of the group technology problem w
subcontracting costs, The overlapping parts are removed from the
matrix in such a way that the total sum’of subcontracting costs is minimiz-
ed.
8.2.2 Mathematical Programming Formulation
*
‘Most mathematical programming models developed in group technology con-
sider a distance measure dj; between parts i and j. The distance measure d;j
is a real valued symmetric function obeying the following axioms:
ty di = 0
+ Symmetry diy =
+ Triangle inequi
For a machine-part incidence matrix [a,j] the most commonly used distance
measures are presented:
1, Minkowski distance measure (Arthanari and Dodge 1981)
where r =a positive integer
m =the number of machines
‘Two special cases of the above measure are widely used:
+ Absolute distance measure (for r = 1)
t + Euclidean distance measure (for r = 2)
2. Weighted Minkowski distance measure (Arthanari and Dodge 1981)
Sec. 8.2 Cluster Analysis Method 227
mi
‘There are two special cases:
+ weighted absolute distance measure
+ weighted Euclidean distance measure
3. Hamming distance measure (Lee 198)
ay =, Bay
mi
1 ifan # ay
0 otherwise
where Bays .ay) = {
Distance measures are also referred to as dissi sures. Some
similarity measures were discussed in the section on effi
methods. In this section, the following mathematical programming models are
discussed:
+ p-median model
+ Generalized p-median model
+ Quadratic programming model
The p-median Model. The p-median model is used
into p part families. In order to consider the p-median mod
variables are defined:
‘m = number of
chines
n= number of parts
p = number of part families
_ | 1 if part é belongs to part family j
*4* 10. otherwise
jj = distance measure between parts / and j
‘The objective function of the p-median models is to minimize the total
sum of distances between any two parts i and j.
(8.24)
subject to 28 Group Technology: Models and Algorithms — Chap. 8
=p (8.26)
for alli =A....ym) f= yee eet (8.27)
Pa dye (8.28)
(8.25) ensures that each part belongs to exactly one part
specifies the required number of part families.
that part i belongs to part family j only when this
required number of part families,
model (8.24)-(8.28) is illustrated in
Example 8.5.
Example 8.5
Given the machine-pat incidence matrix
responding machine cells. For the machi
of Hamming distances is obtained:
umber
the proceeding matrix and p = 2 provides,
and
two part families are formed:
PFI = {1,3}
PR-2 = (2,4,5}
Fr th hf les the corresponding two machine cells are determined from
D:
identical to that
—
8 eee cae
Generalized p-median Model, Model (8.24)-(8.28
oped under the assumption that each part i corresponds to
. kniown as a process plan. To relax this
cel (8.24)(8.28) soar ese
lowing nota
‘n = the total number of process plans
F, = set of process plans for part number k,k = 1... 38
1
UF\=n
p= the maximum required number of part (process) families
dy; = distance measure between process plans 7 and j
= production cost of process plan j
‘The objective of the generalized p-median model
sum of distance measures and production costs.
in 7) at >.
my i
subject to
> Swyet forall =1,. 0.41
ier, j=
ds (3D
xy Sy (8.32)
xy =01 pean (8.33)
Constraint (8.30) ensures that for eu
‘one process plan is selected. Constraint (8
‘number of part fa
(8.27) and (8.28) in the model (8.24)-(8.28), respectively. M
lustrated in Example 8.6.
8.6
Given the machine-part ineidedce matrix (8.34
production costs (8.35), form at most p = 2 pa
cells using model (8.29)-(8.33). (230 Group Technology: Models and Algorithms — Chap. 8
Part number
fo 2" 3 as
Process plan number
123 45 67 89
Eee MET
1 1 Machine
ih 11 | number
hee
(8.34)
he vector of production costs
(835)
=a eS
(8.36)
seoges
for each F,, only one process plan
selected, 29)-{8.33) forthe above data with the LINDO
software produces the fe
and
‘This solution can be interpreted as follows:
PRA = {2,7}
PE2={5,
For these two part fat
from matrix (8.34), two machine cells are obtained:
MC-1 = {2,4}
The final ee
(CRIREE REIS Sie Suswee
Pat Pant
family family
PEL PED
2759
ean
®
4
1
3
Quadratic Programming Model.
(1986) have developed a formulation of the GT problem that allows one to deal
With the restricted number of part fami
tion can be expressed in the form of the
model:
lowing O-1 quadratic programming
aie SS dyxnay (8.38)
Fa ysis tet
subject to
for all i= 1,...4n (8.39)
for all j =1,..64P (8.40)
forall = 1,0..." 7 = (41)
Note that in the above model the following equality holds 5” my =, where
mm, is number of parts in part family j, 1 isthe total number of parts, and p is
the required number of part families.
‘Constraint (8.39) ensures each part belongs to, exactly one part family.
ny parts.
exactly
{8.2.3 Graph Formulation
In the graph formulation, the incidence matri
‘The following three types of graphs can be
is represented by 232 Group Technology: Models and Algorithms = Chap. 8
Pons Machines
Figure 88 Bipasite graph
‘coesponding to matrix (8.1)
* Bipartte graph
+ Transition graph
+ Boundary graph
Bipartite Graph. In the bipartite graph one set of nodes represents
parts and the other machines. In order to discuss the application of bipartite
‘graphs in group technology, consider the graph in Figure 8.8 representing the
incidence matrix (8.1). It can be seen that the bipartite graph in Figure 8.8 |
decomposes into 10 bipartite graphs, shown in Figure 8.9. |
Based on Figure 8.9, the following two part families are formed:
PF-L = {1,3} |
PF-2 = (2,4,5} !
‘The corresponding two machine cells are as follows:
MC-1 = {2,4}
‘MC-2 = {1,3}
t
Figure 89. Two disjoint biparite
graphs for the graph in Figure 8.8, Suboroh 1 ‘Subgraph 2
node, whereas
representing matrix (
ts. To illustrate
Bix (8.3) show
two transition subgraphs are
As the
following two part fami
sponding machine cells are obtained:
PF-1 =(1,2}
Boundary Graph. A boundary graph consists of a hierarch
tite graphs. At each level of the boundary graph, nodes of the bipartite gr
represent either machines or parts. The boundary graph correspondin,
8.1) ina form of two disjoint boundary graphs is shown in Figure 8.13. Each
boundary graph in Figure 8.13 represents a cluster.
“To apply the boundary graph for determining bottleneck parts, consider
mattix (8.3).
‘The boundary graph for matrix (8.3) is presented in Figure 8.14,
Removing parts P; from the boundary graph in Figure 8.14 results in (wo
boundary subgraphs, shown in Figure 8.15
Determining the bottleneck parts or machines in a graph is a rather
ied t0 this problem, Lee. Vogt,
thm to detect the bottlencek
parts or machines. Their algorithm
Let
XV = number of nodes in a graph
= maximum number of nodes in a subgraph
Step 1. Determine the valu
m’ = TN -
teger value not
1) nodes, one for
Step 2.
Step 3. ine the common node of each subgraph. 234 1 Group Technology: Models and Algorithms — Chap. 8 See. 82 Analysis Method 235
Figure 8.14 The
corresponding to
™% Ms
Step 4. Remove the common node from
node to the corresponding subgr
ps 3 and 4 until every node is assigned.
My a
Example 8.7
OM O WY ® Determine th bee sf
Step 1. Assume that K = 3:
Figure 8.13 The boundary, graph comesponding wo mata (81) Step 2. Nodes 2 and 5 have been selected as starting nodes. 236 Group Technology: Models and Algorithms Chap. &
Figure 8.16 a g?. 2
> |Eoeg@22| cl B| le 23
Step 3. Let Z,(Sa88sze| B= a Zs
f2|s3ec222| 3|/2).|82 3e2
(AN) = nodes in graph A : & a5Hei82| 2/€|a) if \e| 452
i CLAN}. ..AC{LB)) = common nodes of graphs A to B & ee duegd BElEle |e |5| 223
Ten j geHEeg ae e
ctcn) = (2,3) E
ee g
12a} = (3, 5} i 2 ae 3 sis gslsl
58 as 2 22/2) 2)2) 2
ADIEU) = 3, ie he common mee o CH} ma cK) BE 2
gS 8
Step 4, Node 3 is removed from C{(1)} and C{(2)}. Adding nodes 2 and $10 bf
the comesponding subgraph gives {(1)} =(1, 2} and C{(2)) ={4, 5} ae eee
Step $. Since there are not any common nodes of C{(1)} and C{(2)} and all Bo BRSe ale olel s
nodes have been assigned, STOP. Be geee 2 2(£)2) 2/2] 2
ae | [S225
Let each node in the preceding example represent a part, then the solution 0 eeii, =
this problem reads as follows: oale ae
= |6| g?
PFI = {1,2 i rd : : 3
iat # lai] 2 alele[#|a) 2
PF2 = {4,5} 3 435
‘The algorithm of Lee, Vogt, and Mickle (1982) was extended in Vane
and Kumar (1986). z
| For euch of the three different formulations of the group technology gE gE -
| problem presented in this chapter, the following three characteristics have been 24 #8 2
7 1 considered: g i € aE £2
| ited number of part families (or machine cells) E = - °
* Limited number of parts in each part family (or machines in each
‘machine cell)
+ Costs (e.g. production, subcontracting)
ed on these characteristics, sample grouping algorithms have been
assigned to each formulation of the GT problem (see Table 8.1).
237
1
L 238 Group Technology: Models and Algo!
n
8.2.4 Nontraditional Application of Group
Technology
fai group technology concept can also be applied to cutting-tool management,
imi a
set of five
parts has soi
tools an incidence matrix (8.42) has been constructed.
Part umber
12345
iPro
2 1 1
3 i ff
4fao4
Tool number ua 8.42)
61
7 1
8 ot
Clustering matrix (8.42) results in matrix (8.43).
Part number
24513
aot
5 1
attra
fe ed
Too! number 7 rT (8.43)
7 1
4 it
6 1
of two clusters of tool
0 corresponding part fa
lustering of pars and tools sim
= {2,5,8,3} and TF-2
s, PF-1 = (2, 4,5} and PF-
ies tool management and part
8.3 CONCLUSION
In this chapter the following two methods of solving the
problem have been discussed ig the group technology
+ Classificat
+ Cluster analysis,
and coding methods, were outlined. The visual method is applicable in a case
Chap.8 References 239
‘when the number of parts is rather limited, Therefore, the coding methods,
which are more commonly used, were discussed.
‘The cluster analysis approach was used to group mac!
cells and parts into part families. To model the group tech
clustering formulations were presented: the matrix formulation,
programming formulation, and graph formulation. Since the GT problem is NP
‘complete, heuristic algorithms are most likely to be used for solving large-scale
‘problems. The results of grouping lead to the physical machine layout
machine layout, The latter is used in a case when the production
‘hanges rather frequently. Group technology applied to tools and parts
simplifies
appropriate for solving large-scale group technology problems.
cedge-based system for group technology (KBCT) presented in the
takes advantage of the efficiency of the cl
group technology problem considered in Chapter 9 is more general that any
‘other problem considered in this chapter and is applicable to automated man-
ufacturing systems.
REFERENCES
T. $. and Y, Dodge (198
John Wiley, New York.
2. Askin, R. and S. Subramanian (1987)
* International Journal of Product
costbased heuristic for group technol-
Research, Nol. 25, No.
M4.
3, Bhat, M. V. and A. Haup
‘Transactions on Systems, Man, and Cybernetics, Ve
4, Burbidge, J. L. (1971), “Prodvetion flow anal
(AprilmMay): pp. 139-152,
116). “An efficient clustering al
SMC-6, No.
No. 1, pp. 65~
6. Chandrasekharan, M. P. and R. Rejagopalan (1986). “MODROC: An.extension of
al Jou
of Pri
7. Cheng, Y. and K. 8. Fu (1985). Conceptual clustering in
IEEE Transactions on Pattern Analysis and Machine In
No. 5, pp. 592-598.
8. De Witte, J. (1980), “The use of similarity coeffi
analysis,” International Journal of Production Research, Vol. 18, No. 4, pp,
). Cluster Analysis, Halsted Press, New York.
* Produetion and Inven
8). “On the synthesis of the loop cut set matrices and the related
Nol. 4, pp. 376-110. 240 Group Technology: Models and Algorithms — Chap. 8 Chap.8 — Problems and Questions ated
fon flow 30. Vannelli, A. and K. R. Kumar (1986)
rational cells for grouping part-machine fami
Research, Vol. 24, No. 2, pp. 387100.
PROBLEMS AND QUESTIONS
Jachine-component group
h using a rank order cl
if Production Research, Vol. 18, No,
King, J. R. and V. Nakornchai (1982)
group tec
Research, Vol. 20, No. 2, pp.
14, Klastorin, T, D. (1982). The p-medt
test using the mixture model approac
Pp. 146.
in
tarional Journal of Production
oblem for cluster analysis: A comparison
s" Maninpeneent Selance; Vol. 31; Na: 1, 8.3. What are the basic differences between the cis
: approaches to group technology’
systems, $8.4. Consider the following matrix formulation ofthe 2
problem in flexible manufactur
Vol. 3, pp. 278-300.
problem,” Working Paper #20/87,
Engineering, University of Manitoba,
Part number
16, Kusiak, A. ¢
12345678
Department of Mechanical and Indust
Winnipeg, Canada,
\
17. isis, A and W. S. Chow (19870, “An algorithm for cluster nie aft 1
| IEEE Tronsacrons on Systems, Man, and Cybernetics. Vol. SMC-17, No. 4. pp 3] 4 \ 1
| 626-099 aii 1 8
| 18, Kusak, A. and W. S. Chow (1987), “Efficient solving of the group techloes Machine 5 js
sournal of Manufacturing Stems, Vol. 6, No.2, pp. 117-124 war is}! i
is “Deconpsion of sufctung ssn, eae
iomaton, Vol 4, No. 3, pp. 4571 5 eae.
» and KR. Kumar (1986), “Cstering analysis: Modes wl ot 1
Chbeneics, NOL 13, No.2, ps 3915.
x tution of hart paths Solve the problem by
. Singleinkagechstr atl apposch
Rank ede luting algo
2 ' €. Dire clase
Eb) Bond ener
3. bender. J. (1972), “Machine grouping for efficient production,” The Production ¢. Extended cluster i
ar Boba. pp. 5357. Analyze the eompuatinal processes andre.
2s, MeComih W. Te P I. Sate 4.5, Consider he following group tenology problem
| posiion and data organization by clue tehniue." Operations Research, Val aes
Bo. No.3 pp. 95-1009, ere
25, Nagai S. Tei and, Shing (1980), “Determination of similar skype eae
mn method: Towards improving quality
rarional Journal of Production Research,
3 into weakly coupled
components,” IFAC 9th World Congress, Budapest, Hungary, July 2-6. algorithms
28. Slagle, J. L.. C. L. Chang, and S, R. Heller (1975). “A clustering and data ‘a, Single-linkage cluster analysis
algorithm,” IEEE Transactions on Systems, Man, and Cybernetics, D. Rank order clustering algor
Direct cluster algorithm
TT, and R, C, Gonzalez (1974). Pattern Recognition Principles, Addison- 4. Bond energy algorithm
Wesley. Reading, Mass. ¢. Cluster identification algori 242 Group Technology: Models and Algorithms Chap. 8
8.6. For the matrix in Problem 8.4 formulate the p-median model and solve it for
rent number of part families p. Discu
Problem 8.5, formal
the matrix in Problem 8.5 add an arbitrary
and solve the generalized p-median model.
‘and weaknesses of the quadratic programming formulation
of the group technology problem.
8.10. For each of the incidence matrices in Problems 8.4 and 8.5, build a come-
sponding
1. Bipartte graph
b. Transition graph
. Boundary graph
before clustering and after the matrices have been clustered.
- Apply the Lee's algorithm to the matrix in Problem 8.4.
ns of group technology.
i of group technology in the applications named in Problem
's a formulation of the group technology problem involving 0-1
‘machine-part incidence motrix?
8.15, What is a bottleneck machine?
an example using a machine-
part
Input File for the Problem in Example 8.5
APPENDIX 8.1
INPUT FILE FOR THE PROBLEM IN EXAMPLE 8.5
MIN
4X12+4X1443K1544X21 44X2341X25+EXI2HIKIS +
3X35 +4X41-+4X43+ 1X45+3NS1+1X5243XS341 X54
SUBJECT TO
XU+X12+X134X144X15"1
X21+K22+X234X244K25=1
X314K32+X334K344535=1
X414+X424X434 X44 K45=1
XS1+X524X534XS44K55=1
X114X224K334X442X55=2
XOL-Xi1<=0
3B1-X11<=0
XAL-XI1<=0
XSL-XIL<=0
X12-X22<=0
XB2X22<0
X42-X22<<0
X52-X22<=0
X13-X33<=0
X23-X33<=0
X43-X33<=0
X53-X33<=0
X14-x44<=0
24-X44<=0
X34-X44<=0
X34-X4d<=0
X1S-X55.
X25-X55.
X35-X35<=0
X4S-X95<=0
243, 244 Group Technology: Models and Algorithms — Chap. & input File for the Problem in Example 8.2
APPENDIX.8.2 APPENDIX 8.2 (continued)
X63-X33 <0
INPUT FILE FOR THE PROBLEM IN EXAMPLE 8.6
MIN
‘999X12+999K13+2X ld+2X15+2X16+2X17+2X18+2X19 +
DK3944X310+1 X31] +2X41+2X42+2K43+999X45+4X46 +
‘2K4744X48+2X4942X410+3X411 42X51+4X5242X53 +
999X54+2X56+4X57+2X58+2XS10F1XS11 42X61+2X62 +
2X634+4K64+2X65+999X67+2X69+2X610+1XO11 +2X71 +
2X7342X744+4X754999X76+2X78+4X7942X710+3X71
2XB142X82+2X8344XE442X85+2X87+999X80+2X810+ 1X8
1 +3X11al+3X1 1241 X113+3X 11441 X1 15 41X16 +
1+1X118+1X119 +999X1110
SuBIECT TO
XIX 120X134 402 SIG OIT ARIES XIAN OOK
X14 X42 X434X 44 1X45 +X4GHXAT#X4BANADXALONXALL +
XS14X5S2+K534X54+X95+K56+KS74X584X594X5S104XS11 = 1
X61+X624X634 X614+X65+X66+X674X68+X69+X610+X611 +
XTEXT2+XT34X 744 X7SAXT6+XTT#XTB4X794X7104X711 = 1
XB1+X82+X83+X84+X85+X 86+ K87+XBB1X89+XB10+XB11 +
X914X924X93+X94+X95+X96+K97+XOB4X994X9104X911 = 1
X101+X102+X103+X104+X105+X106+X107+X108+X109 +
X68-X88
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