A complete cellular manufacturing system design methodology based on axiomatic design principles

Abstract

This paper provides a framework and a road map for people who are ready to transform their traditional production system from process orientation to cellular orientation, based on Axiomatic Design (AD) principles. A feedback mechanism for continuous improvement is also suggested for evaluating and improving the cellular design against pre-selected performance criteria. A complete implementation of the proposed methodology at a manufacturing company and resulting performance improvements are also provided.

Introduction

With the increasing popularity of lean thinking, cellular manufacturing has become a significant focal point in manufacturing. In concert with this development, there have been numerous publications on design and improvement of cellular manufacturing systems (CMSs). Among these, we can list part family and machine group determination (Nancy & Wemmerlöv, 2002), evaluation of grouping efficiency measures (Sarher & Mondal, 1999), group scheduling (Wemmerlöv, 1992), machine layout in cells (Aneke & Carrie, 1986) and capacity planning in cellular manufacturing (Sule, 1991). Numerous modeling techniques have also been proposed for part family and machine group determination, including visual analysis (Burbridge, 1969; Groover, 1987), coding and classification (Choi, 1992; Hyer & Wemmerlöw, 1987), clustering algorithms (Singh & Rajamani, 1996), mathematical methods (Heragu & Chen, 1998; Sofianopoulou, 1999) and artificial intelligence approaches (Soleymanpour, Vrat, & Shankar, 2002; Zhao & Wu, 2000). All these approaches are developed to satisfy only one or limited functional requirements of the CMS design. Approaches, which include all aspects of cellular system design, are very limited. Silveira (1999) provides one such approach. This approach intends to integrate concepts and techniques into an integrated system in a logical sequence. This approach, however, is mostly based on his past experience and lacks detailed principles for implementation. With its scientific basis, the authors believe that axiomatic design (AD) approach (Suh, 1990) will provide a sound and systematic basis to cellular manufacturing design.

Many AD applications in designing products, systems, organizations and software have appeared in the literature in the last 10 years. AD theory and principles have been introduced first time by Suh (1990). Black and Schroer (1988) provide definition and use of decouplers for achieving flexibility in CMSs. Gunasekera and Ali (1995) have provided a three-stage approach to metal forming process. The stages are composed of conceptual stage, initial stage and final stage, respectively. The conceptual stage is designed using AD approach. Suh (1997) provided a conceptual approach for defining, classifying and design of systems using AD methodology. Suh, Cochran & Paulo (1988) provided an AD-based model for an ideal production system in line with lean principles. Babic (1999) provides a decision support system for arrangement of flexible manufacturing systems. This approach uses AD design principles together with FLEXY intelligent system. Cochran, Eversheim, Kubin, and Sesterhenn (2000) convert complex production system into small, flexible and decentralized production segments. In this approach they use lean principles in conjunction with segmentation and AD principles. Cochran, Kim & Kim (2000) provide a performance evaluation system for production system. Chen, Chen, and Lin (2000) proposed a knowledge-based decision support system using independence axiom of AD in order to improve cell performance. Houshmand and Jamshidnezhad (2002) also provide a lean manufacturing based production system design model using AD approach. In this model organizational capabilities, technological capabilities and value stream analysis are used as the basis. In addition to the design of manufacturing systems, AD approach has also been used in software design (Kim, Suh, & Kim, 1991), product design (Tseng & Jiao, 1997) and quality system design (Suh, 1995) areas. These studies have convincingly shown the applicability and benefits of AD in solving industrial problems.

Considering the literature mentioned above, a road map including all functional requirements of CMS design is not found. In this study, a methodology is developed using AD principles in order to fill this void in the design process.