A series—parallel redundant reliability system for cellular manufacturing design

Abstract

This paper presents a novel, multi-objective mixed-integer programming model for designing a cellular manufacturing system (CMS) that minimizes the total cost and maximizes the overall system reliability. In general, it is impossible to avoid production interruptions while handling machine breakdowns. In this situation, changing the process route dynamically can provide a quick response to meet production requirements. By assuming alternative process plans for operation—part requirements, the concept of the ‘reliable route’ proposed in the literature is extended. In a redundant reliability system with a series—parallel configuration, each reliable route is associated with an operation of a part (i.e. an operation—part) as a parallel subsystem. This route consists of a number of units or alternative machines allocated to cells in such a way that parts are processed with the maximum reliability for a given period of time. When an alternative machine breaks down, unprocessed parts are transferred to the next predetermined machine on the reliable route in order to complete their processes. While the reliable route approach increases the overall system reliability, the operational costs of the system also increase. To assess the present proposed model as a useful decision tool for the manager, various numerical examples are solved and analysed. Finally, the related computational results are reported.