Revision Tutorial on Manufacturing Systems Date 10-Sep-23

Revision Tutorial on Manufacturing Systems

Introduction:
• The Rank Order Clustering C ASSEMBLY B A

(ROC) is another method to 11 12 14

assign Part Families to specific 13 15
Machine Cells in order to
convert a Process or Functional 1 2 4 5 8
Manufacturing setup into a
3 6 7 9 10
Cellular Manufacturing layout.
• In our last lecture we have A RAW MATERIALS B C

discussed about a function type Figure: Functional Layout of Manufacturing

1
 of layout which are meant for Batch Production where the focus
is largely on volume of manufacture.
• In a manufacture of large volume of product generally the variety
is less. ASSEMBLY
A B C
• The need of present day is
larger variety of product. 9 10 15 6 5

• In large variety products the 13

product families are larger, for 14 4 3
2
example different models of
cars will have different sizes of 1 11 7 8 12
engines and drive systems; or
different cell phones will have A RAW MATERIALS B C

different hardware and Figure: Cellular Layout of Manufacturing

2
 software; different buildings will require different variety of
construction materials.
• A larger variety demands a Cellular Manufacturing where the
part-families which belong to a particular cell are fully contained
in the cell itself.
• An example of a Cellular manufacturing is shown in the figure.
• The problem that arises is how to convert a Functional
manufacturing Layout into a Cellular Layout.
• We have seen one method of changing a Functional Layout to
the Cellular Layout by adopting the Production Flow Analysis
in the last lecture.
• In this lecture we are going to study another method which has
gained in important due the modern methods in manufacturing.
• The method is known as the Rank Order Clustering.
3
Rank Order Clustering:
• We shall explain the Rank Order Clustering (ROC) with the help
of an example. INCIDENCE MATRIX

• Let us consider an
Part Families
Machines 1 2 3 4 5 6 7 8
example where there are 1 1 1 1
2 1 1
8-Parts and 7-Machines 3 1 1 1 1
in a manufacturing 4 1 1 1
5 1 1 1
system. 6 1 1 1
7 1 1
• These machines are laid
out in a fashion to yield a Batch type production as shown in the
table.

4
• We have studied earlier that this table is known as the Incidence
Matrix where all machines are listed in the first column to the left
and all parts are listed on the top most row.
• When a part visits a machine the corresponding entry of the
matrix is denoted as 1 and if it does not visit a machine that
entry is 0.
INCIDENCE MATRIX
• The size of the matrix Part Families

shown is 7 × 8 which is a Machines

1
1 2
1
3 4 5 6
1
7 8
1
very small size compared 2 1 1
3 1 1 1 1
to a practical size where 4 1 1 1
5 1 1 1
the number of machines 6 1 1 1
and parts may be much 7 1 1

larger.

5
• In the incidence matrix shown above the Part number 2 visits
the Machine number 4 hence the entry at fourth row and second
column is written as 1. While the Part-2 does not visit the
Machine-2 hence the entry is 0 or blank. (a blank is considered
to be 0 in Excel etc.)
• The Rank Order Clustering is a simple algorithm that is being
used extensively and is based on very simple principles.
• In this method a weight is assigned to each row of the matrix or
to each machine.
• Similarly a weight is assigned to each column of the matrix or
each part family.
• First we shall consider the assignment of weights to the rows.

6
Assignment of Weights:
• In the above incidence matrix there INCIDENCE MATRIX
Part Families
Machines 1 2 3 4 5 6 7 8
are 7 rows which take 7 positions in 1 1 1 1
2 1 1
the matrix. 3 1 1 1 1
4 1 1 1

• The Row-1 has the following entries 5

6
1
1 1
1 1
1
7 1 1
in the matrix: : 0,1,0,0,0,1,0,1
• There are 8 entries in the row and we will assign weights to
each one of the entries. INCIDENCE MATRIX

• The weights are assigned as 2's exponent 7 6 5

Part Families
4 3 2 1 0
2’s exponent such as: Exp.va l ue 128 64 32 16 8 4 2 1
Machines 1 2 3 4 5 6 7 8
20 , 23 , 24 , 25 , 26 𝑎𝑛𝑑 27 . 1 1 1 1

• The positions are considered 2 1 1

3 1 1 1 1
from the last column as 4 1 1 1
5 1 1 1
7 6 1 1 1
7 1 1
 normally done for a binary numbering system, in other words the
last column or the 8th column will be assigned a weight 20 or 1.
• The 7th column will be assigned a weight of 21 or 2.
• In the same sequence the weight for the 6th column will be 22 or
4 etc. till first column weight of
INCIDENCE MATRIX
27 or 128. Part Families

• 7 6 5 4 3 2 1 0
2's exponent
This process is followed and the Exp.va l ue 128 64 32 16 8 4 2 1
weights of the different columns Machines 1 2 3 4 5 6 7 8
1 1 1 1
are respectively: 1, 2, 4, … , 128. 2 1 1
• The weights are entered on the 3 1 1 1 1
4 1 1 1
topmost row of the incidence 5 1 1 1
matrix as shown in the figure. 6 1 1 1

•
7 1 1
The entries of the incidence

8
 matrix are multiplied by the weights of the corresponding column
and like that the weights of the rows starting from Machine-1 to
Machine-7 are calculated.
• The calculation of the weights of each row is shown below:

Weight Calculation of each Row:

For the first row is: 1 × 20 + 1 × 22 + 1 × 26 = 1 + 4 + 64 = 69
For the second row: 1 × 22 + 1 × 24 = 4 + 16 = 20
For the third row: 1 × 20 + 1 × 21 + 1 × 23 + 1 × 27 = 1 + 2 + 8 +
128 = 139
For the fourth row: 1 × 20 + 1 × 25 + 1 × 26 = 1 + 32 + 64 = 97

9
 For the fifth row: 1 × 21 + 1 × 23 + 1 × 27 = 2 + 8 + 128 = 138
For the sixth row: 1 × 20 + 1 × 25 + 1 × 26 = 1 + 32 + 64 = 97
For the seventh row: 1 × 22 + 1 × 24 = 4 + 16 = 20
The weights calculated for each row is entered in the right most
column of the matrix as:

10
 INCIDENCE MATRIX
Part Families
2's exponent 7 6 5 4 3 2 1 0
Exp.va l ue 128 64 32 16 8 4 2 1
Machines 1 2 3 4 5 6 7 8 Weights
1 1 1 1 69
2 1 1 20
3 1 1 1 1 139
4 1 1 1 97
5 1 1 1 138
6 1 1 1 97
7 1 1 20

11
• The next thing is sort the rows as per the weights as shown:

Machines 1 2 3 4 5 6 7 8 Weights
3 1 1 1 1 139
5 1 1 1 138
4 1 1 1 97
6 1 1 1 97
1 1 1 1 69
2 1 1 20
7 1 1 20

• Now repeat the same steps to assign weights for the columns or
the Part Families.

12
• There are 7 entries in the columns and we will assign weights to
each one of the entries.
• Same way as before the weights are assigned as 2’s exponent
such as: 20 , 23 , 24 , 25 𝑎𝑛𝑑 26 .
• The positions are considered from the last row of the matrix as
normally done for a binary numbering system, in other words the
last row or the 7th row will be assigned a weight 20 or 1.
• The 6th row will be assigned a weight of 21 or 2.
• In the same sequence INCIDENCE MATRIX
Part Families
th
the weight for the 5 row Machines 1 2 3 4 5 6 7 8 2's exp. Exp.va l ue
3 1 1 1 1 6 64
2
will be 2 or 4 etc. till first 5 1 1 1 5 32
4 1 1 1 4 16
row where the weight of 6
1
1
1
1
1
1
1
3
2
8
4
6
2 or 64. 2
7
1
1
1
1
1
0
2
1

13
 INCIDENCE MATRIX
• This process is followed Machines 1 2 3
Part Families
4 6 7 58 2's exp. Exp.va l ue

and the weights of the 3

5
1
1
1
1
1
1
1 6
5
64
32
different rows are 4
6
1
1
1
1
1
1
4
3
16
8

respectively: 1, 2, 4, … , 64. 1
2
1
1
1
1
1 2
1
4
2

• The weights are entered 7 1 1 0 1

on the right-most row of the incidence matrix as shown in the

figure.
• The entries of the columns of the incidence matrix are multiplied
by the weights of the corresponding rows and like that the
weights of the rows starting from Part-1 to Part-8 are calculated.
• The calculation of the weights of each column is shown below:

14
Weight Calculation of each Column:
For the first column is: 1 × 25 + 1 × 26 = 32 + 64 = 96
For the second column: 1 × 22 + 1 × 23 + 1 × 24 = 4 + 8 + 16 =
28
For the third column: 1 × 23 + 1 × 24 = 8 + 16 = 24
For the fourth column: 1 × 20 + 1 × 21 = 1 + 2 = 3
For the fifth column: 1 × 25 + 1 × 26 = 32 + 64 = 96
For the sixth column: 1 × 20 + 1 × 21 + 1 × 22 = 1 + 2 + 4 = 7
For the seventh column: 1 × 25 + 1 × 26 = 32 + 64 = 96
For the eighth column: 1 × 22 + 1 × 23 + 1 × 24 + 1 × 26 = 4 +
8 + 16 + 64 = 92
15
 The weights calculated for each column is entered in the bottom
most row of the matrix as shown below:
INCIDENCE MATRIX
Part Families
Machines 1 2 3 4 5 6 7 8 2's exp. Exp.va l ue
3 1 1 1 1 6 64
5 1 1 1 5 32
4 1 1 1 4 16
6 1 1 1 3 8
1 1 1 1 2 4
2 1 1 1 2
7 1 1 0 1
Col. Wts. 96 28 24 3 96 7 96 92

16
• It may be noted that the column weights are not in decreasing
order, hence we have to sort the matrix entries by the weights
given in the last row. The matrix after sorting is shown below:
Sort the columns as per the Row Weights given in the last row

INCIDENCE MATRIX
Part Families
Machines 1 5 7 8 2 3 6 4
3 1 1 1 1
5 1 1 1
4 1 1 1
6 1 1 1
1 1 1 1
2 1 1
7 1 1
Row Wts. 96 96 96 92 28 24 7 3
17
• The matrix shown the Clustered matrix.
• In other words it is in a near block diagonal form of matrix –
except for the part family 8 and 6 the other parts only go to
machine of the particular cell.
• Each block can now be considered as a Cell.
• The part family 8 is assigned to Cell-2 but it requires machining
by Machine-3 which is in Cell-1. And the part family 6 is
assigned to Cell-3 but it requires machining by the machine-1
which belongs to Cell-2.
• This indicates that there are two inter-cell moves one is by Part-
8 and the other is by Part-6. This can be also managed by
adding two extra machines M-3 and M1.

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Example-1
A manufacturing system was originally laid out for facilitating mass
production with Functional Manufacturing. The machines were laid
out to assist the Functional Manufacturing and are denoted as
machine M1 to M4. The part-families being manufacture are
denoted as P1 to P4. The layout of the machines and parts are
denoted conventionally by a matrix given below:
INCIDENCE MATRIX
Part Families
Machines P1 P2 P3 P4
M1 1 1
M2 1 1
M3 1 1
M4 1 1
19
Reconfigure the layout the machines to support Cellular
Manufacturing such that machines and part form clusters. Use
Rank Order Clustering method to cluster the machines and parts.
Solution:
Start with clustering the machines using 2’s exponent:
INCIDENCE MATRIX
Part Families
2's exponent 3 2 1 0
Exp.value 8 4 2 1
Machines P1 P2 P3 P4 Weights
M1 1 1 10
M2 1 1 5
M3 1 1 5
M4 1 1 10
20
Weights: M1:8+2=10; M2:4+1=5; M3:4+1=5; M4:8+2=10
Next we sort the Rows of the Incidence Matrix as per the weights:
CLUSTERED MATRIX
Part Families
2's exponent 3 2 1 0
Exp.value 8 4 2 1
Machines P1 P2 P3 P4 Weights
M1 1 1 10
M4 1 1 10
M2 1 1 5
M3 1 1 5

21
Next we assign weights to the part families as shown below:
CLUSTERED MATRIX
Part Families
Machines P1 P2 P3 P4 2^n n
M1 1 1 8 3
M4 1 1 4 2
M2 1 1 2 1
M3 1 1 1 0
Weights 12 3 12 3

Weights: P1:8+4=12; P2:2+1=3; P3:8+4=12; P4:2+1=3;

22
Next we sort the Columns by the weights assigned to part families:
CLUSTERED MATRIX
Part Families
Machines P1 P3 P2 P4
M1 1 1
M4 1 1
M2 1 1
M3 1 1
Weights 12 12 3 3

23
Example-2
A manufacturing system was originally laid out for facilitating mass
production with Functional Manufacturing. The machines were laid
out to assist the Functional Manufacturing and are denoted as
machine M1 to M4. The part-families being manufacture are
denoted as P1 to P4. The layout of the machines and parts are
denoted conventionally by a matrix given below:
INCINDENCE MATRIX
Part Families
Machines P1 P2 P3 P4 P5
M1 1 1 1
M2 1 1
M3 1 1 1
M4 1 1
24
Reconfigure the layout the machines to support Cellular
Manufacturing such that machines and part form clusters. Use
Rank Order Clustering method to cluster the machines and parts.
Solution:
INCINDENCE MATRIX
Part Families
n 4 3 2 1 0
2^n 16 8 4 2 1
Machines P1 P2 P3 P4 P5 Weights
M1 1 1 1 11
M2 1 1 20
M3 1 1 1 11
M4 1 1 20
Weights: M1:8+2+1=11; M2:16+4=20; M3=8+2+1=11; M4:16+4=20

25
 CLUSTERED MATRIX
Part Families
2's exponent 4 3 2 1 0
Exp.value 16 8 4 2 1
Machines 1 2 3 4 5 Weights
2 1 1 20
4 1 1 20
1 1 1 1 11
3 1 1 1 11

26
 CLUSTERED MATRIX
Part Families
Machines 1 2 3 4 5 2^n n
2 1 1 8 3
4 1 1 4 2
1 1 1 1 2 1
3 1 1 1 1 0
12 3 12 3 3

CLUSTERED MATRIX
Part Families
Machines 1 3 2 4 5
2 1 1
4 1 1
1 1 1 1
3 1 1 1
Weights 12 12 3 3 3
27
Example-3
A manufacturing system was originally laid out for facilitating mass
production with Functional Manufacturing. The machines were laid
out to assist the Functional Manufacturing and are denoted as
machine M1 to M4. The part-families being manufacture are
denoted as P1 to P4. The layout of the machines and parts are
denoted conventionally by a matrix given below:
INCIDENCE MATRIX
Part Families
Machines 1 2 3 4 5
1 1 1
2 1 1 1
3 1 1
4 1 1 1
28
Reconfigure the layout the machines to support Cellular
Manufacturing such that machines and part form clusters. Use
Rank Order Clustering method to cluster the machines and parts.
Solution:
n 4 3 2 1 0
2^n 16 8 4 2 1
Machines P1 P2 P3 P4 P5 Wt.
M2 1 1 1 26
M4 1 1 1 26
M1 1 1 5
M3 1 1 5

29
 Machines P1 P2 P4 P3 P5
M2 1 1 1 8 3
M4 1 1 1 4 2
M1 1 1 2 1
M3 1 1 1 0
Weights-> 12 12 12 3 3

•
•
•
•
•
•

30
31