Design of virtual manufacturing cells: a mathematical programming approach

In this paper, a new type of virtual cellular manufacturing (CM) system is considered, and a multi-objective design procedure is developed for designing such cells in real time. Retaining the functional layout, virtual cells are addressed as temporary groupings of machines, jobs and workers to realize the benefits of CM. The virtual cells are created periodically, for instance every week or every month, depending on changes in demand volumes and mix, as new jobs accumulate during a planning period. The procedure includes labor grouping considerations in addition to part-machine grouping. The procedure is based on interactive goal programming methods. Factors such as capacity constraints, cell size restrictions, minimization of load imbalances, minimization of inter-cell movements of parts, provision of flexibility, etc. are considered. In labor grouping, the functionally specialized labor pools are partitioned and regrouped into virtual cells. Factors such as ensuring balanced loads for workers, minimization of inter-cell movements of workers, providing adequate levels of labor flexibility, etc. are considered in a pragmatic manner.