Quantitative analysis in Cellular

Manufacturing
Rank Order Clustering Method

• It also known as binary ordering algorithm (BOA), It is a simple algorithm used to form
machine-part groups. it was Developed by J.R.King (1980).

• It considers two data:

A.U.MEENAKSHI SUNDARESWARAN
• Number of components and Component sequences. Based on the component sequences, a
machine-part incidence matrix is developed.

• Rows of the machine component incidence matrix represent the machines which are
required to process the components. Columns of the matrix represent the component
numbers.

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Quantitative analysis in Cellular
Manufacturing
Concept:

• Each row and each column of the matrix are considered as binary words.

Example, in a row if we have numbers (1 0 1 0 1), then the decimal equivalent is computed

A.U.MEENAKSHI SUNDARESWARAN
•
as follows:

• Row decimal equivalent = (1× 24) +(0×23) + (1 × 22) + (0 × 21) + (1 × 20)

= 16 + 0 + 4 + 0+ 1 = 21

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Quantitative analysis in Cellular
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Concept:

• If a column has the following entries from top to bottom, the decimal equivalent is computed
as explained below:

• Column entries = (11010)

• Column decimal equivalent = (1 × 24) + (1 × 23) + (0 × 22) + (1 × 21) + (0 × 20)

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= 16 + 8 + 0 + 2 + 0 = 26

• Row with the largest decimal equivalent is considered to have the highest rank 1 among the
rows.

• Column with the largest decimal equivalent is considered to have the highest rank among
the columns.

• Procedure to obtain final machine component incidence matrix is summarized below.

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Quantitative analysis in Cellular
Manufacturing
Steps in ROC Algorithm

The steps in ROC algorithm are given below:

Step 0: Input: Total number of components, component sequences.

A.U.MEENAKSHI SUNDARESWARAN
Step 1: Form the machine-component incidence matrix using the component sequences.

Step 2: Compute binary equivalent of each row.

Step 3: Rearrange the rows of the matrix in rank wise (high to low from top to bottom).

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Quantitative analysis in Cellular
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Steps in ROC Algorithm

Step 4: Compute binary equivalent of each column and check whether the columns of the
matrix are arranged in rank wise (high to low from left to right). If not, go to Step 7.

A.U.MEENAKSHI SUNDARESWARAN
Step 5: Rearrange the columns of the matrix rank wise and compute the binary equivalent of
each row.

Step 6: Check whether the rows of the matrix are arranged rank wise, If not, go to Step 3;
otherwise, go to Step 7.

Step 7: Print the final machine-component incidence matrix.

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Quantitative analysis in Cellular
Manufacturing
Arranging Machines in a GT cell

There are three basic ways to arrange machines in a GT cell are :

1. Line (or product) layout.

A.U.MEENAKSHI SUNDARESWARAN
2. Functional (or process) layout.

3. Group (or combination) layout.

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Quantitative analysis in Cellular
Manufacturing
1) Line (or Product) Layout

• Here the machines are arranged in the sequence as required by the product.

• If volume of production of one or more products is large, the facilities can be arranged to
achieve efficient flow of materials and lower cost per unit.

A.U.MEENAKSHI SUNDARESWARAN
Suitability:

• Suitable for the continuous mass production of goods as it makes it possible for the raw
material to be fed into the plant and take out finished product on the other end.

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Quantitative analysis in Cellular
Manufacturing

A.U.MEENAKSHI SUNDARESWARAN
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Quantitative analysis in Cellular
Manufacturing
2) Functional (or Process) Layout

• Characterized by keeping similar machines, operations at one location, i.e. all lathes at one
place, all milling machines at another place.

• In process layout, machines are arranged according to their functions.

Suitability: Suitable for job order/non-repetitive type production.

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Quantitative analysis in Cellular
Manufacturing

A.U.MEENAKSHI SUNDARESWARAN
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Quantitative analysis in Cellular
Manufacturing
3) Group (or Combination) Layout

• It is a combination of the product layout and process layout.

• This layout Combines the advantages of both layout systems.

• Here machines are arranged into cells , each cell is capable of performing manufacturing
operations on one or more families of part.

A.U.MEENAKSHI SUNDARESWARAN
• If there are m machines and n components, in a group layout, the m-machines and n -
components will be divided into distinct number of machines-component cells (groups) such
that all the components assigned to a cell are almost processed within that cell itself.

• Objective is to minimize the inter-cell movements.

Suitability: Preferred for batch type production, where the products are m
batches and in large variety.

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Quantitative analysis in Cellular
Manufacturing
3) Group (or Combination) Layout

A.U.MEENAKSHI SUNDARESWARAN
• If there are m machines and n components, in a group layout, the m-machines and n -
components will be divided into distinct number of machines-component cells (groups) such
that all the components assigned to a cell are almost processed within that cell itself.
• Objective is to minimize the inter-cell movements.
Suitability: Preferred for batch type production, where the products are m
batches and in large variety.
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Quantitative analysis in Cellular
Manufacturing

A.U.MEENAKSHI SUNDARESWARAN
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Hollier Method-Simple Problems
Hollier Method 1:
• The first method uses the sums of flow "From" and "To" each machine in the cell. The
method can be outlined as follows:
1. Develop the From—To chart from part routing data. The data contained in the chart
indicates number of part moves between the machines for workstations)

A.U.MEENAKSHI SUNDARESWARAN
2. Determine the "From” and "To" sums for each machine. This is accomplished by
summing all of the "From" trips and "To" trips for each machine (or operation ).The "From"
sum for a machine is determined by adding the entries in the corresponding row and the "To"
sum is found by adding the entries in the corresponding column.

3. Assign machines to the cell based on minimum "From" or To sums. The machine
having the smallest sum is selected. If the minimum value is a "To" sum, then the machine is
placed at the beginning of the sequence. If the minimum value is a “From” sum, then the
machine is placed at the end of the sequence. Tie breaker rules:

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Hollier Method-Simple Problems
Hollier Method 1:

(a) If a tie occurs between minimum. "To" sums or minimum "From" sums, then the machine
with the minimum “From/To” ratio is selected.

A.U.MEENAKSHI SUNDARESWARAN
(b) If both "To" and "From" sums are equal for a selected machine, it is passed over and the
machine with the next lowest sum is selected.

(c) If a minimum "To" sum is equal to a minimum "From" sum, then both machines are
selected and placed at the beginning and the end of the sequence respectively.

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Hollier Method-Simple Problems
Hollier Method 1:

(a) If a tie occurs between minimum. "To" sums or minimum "From" sums, then the machine
with the minimum “From/To” ratio is selected.

(b) If both "To" and "From" sums are equal for a selected machine, it is passed over and the
machine with the next lowest sum is selected.

A.U.MEENAKSHI SUNDARESWARAN
(c) If a minimum "To" sum is equal to a minimum "From" sum, then both machines are
selected and placed at the beginning and the end of the sequence respectively.

• Reformat the From-To chart After each machine has been selected, restructure the From-To
chart by eliminating the row and column corresponding to the selected machine and
recalculate the "From" and "To" sums. Repeat steps 3 and 4 until all machines have been
assigned.
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Hollier Method-Simple Problems
Hollier Method 2:

• This approach is based on the use of From/To ratios formed by summing the total flow from
and to each machine in the cell. The method can be reduced to three steps:

1. Develop the From—To chart. This is the same step as in Hollier Method 1.

A.U.MEENAKSHI SUNDARESWARAN
2. Determine the From/To ratio for each machine. This is accomplished by summing up
all of the "From" trips and "To" trips for each machine (or operation). The "From" sum for a
machine is determined by adding the entries in the corresponding row and the "To" sum is
determined by adding the entries in the corresponding column. For each machine, the
From/To ratio is calculated by taking the "From" sum for each machine and dividing by the
respective "To" sum.

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Hollier Method-Simple Problems
Hollier Method 2:

• 3. Arrange machines in order of decreasing From/To ratio. Machines with a high

From/To ratio distribute work to many machines in the cell but receive work from few
machines. Conversely machines with a low From/To ratio receive more work than they
distribute. Therefore, machines are arranged in order of descending From/Ip ratio. That is,
machines with high ratios are placed at the beginning of the work flow and machines with

A.U.MEENAKSHI SUNDARESWARAN
low ratios are placed at the end of the work flow. In case of a tie, the machine with the
higher "From" value is placed ahead of the machine with a lower value.

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Hollier Method-Simple Problems
Percentage of in-sequence moves

• Percentage of backtracking moves.

• The percentage of in sequence moves is computed by adding all the values representing in

A.U.MEENAKSHI SUNDARESWARAN
sequence moves and dividing by the total number of moves.

• The percentage of back tracking moves is determined by summing all of the values
representing back tracking moves and dividing by the total number of moves.

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