Cell Loading and Product Sequencing Subject to Manpower Restrictions in Synchronized

Cell Loading and Product Sequencing Subject to Manpower Restrictions in Synchronized Manufacturing Cells

A thesis presented to the faculty of the Russ College of Engineering and Technology of Ohio University

In partial fulfillment of the requirements for the degree Master of Science

Fatih Yarimoğlu March 2009

© 2009 Fatih Yarimoğlu. All Rights Reserved.

2 This thesis titled Cell Loading and Product Sequencing Subject To Manpower Restrictions in Synchronized Manufacturing Cells

by FATİH YARIMOĞLU

has been approved for the Department of Industrial and Systems Engineering and the Russ College of Engineering and Technology by

Gürsel A. Süer Professor of Industrial and Systems Engineering

Dennis Irwin Dean, Russ College of Engineering and Technology

3 ABSTRACT YARIMOĞLU, FATİH, M.S., March 2009, Industrial and Systems Engineering Cell Loading and Product Sequencing Subject to Manpower Restrictions in Synchronized Manufacturing Cells (185 pp.) Director of Thesis: Gürsel A. Süer The main characteristic of the problem is that it considers a synchronized environment. A scheduling problem is handled in a manufacturing system that is using uniform time bucket approach for synchronization. There are three main aspects of the problem. The first aspect is the allocation of manpower. The manpower levels are determined in order to maximize production rate. Then, cell loading issue is addressed for multiple cells. Finally, a schedule is generated for each cell in order to minimize the number of periods where available manpower is exceeded. Two methods are used in order to solve these three main aspects of the problem, namely mathematical modeling and genetic algorithm. It has been concluded that mathematical modeling is better for cell loading and genetic algorithm is better for product sequencing. Also, minimizing similarity among products worked better during cell loading phase. Finally, sequential solution of cell loading and product sequencing was...