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Coping with the Loss of Pooling Synergy in Cellular Manufacturing Systems

Author

Listed:
  • Nallan C. Suresh

    (School of Management, State University of New York at Buffalo, Buffalo, New York 14260)

  • Jack R. Meredith

    (College of Business Administration, University of Cincinnati, Cincinnati, Ohio 45221-0130)

Abstract

The conversion of a functional layout into a cellular manufacturing system involves the partitioning of several multiserver work centers. The loss of pooling synergy in this process can be significant, and this paper investigates the impact of several measures to overcome the adverse effects on flow time, work-in-process inventory and machine utilization. These can be alleviated to a certain extent through reductions in setup times and lot sizes that has been traditionally emphasized in group technology, but a more concerted effort is required. Analytical models are first utilized to investigate the extent to which these adverse effects can be overcome through (1) reduction in setup time, (2) lot sizing, (3) reduction in the variability of process-times and job arrivals, and, (4) reduction in processing times through productivity improvements, all arising from part family-oriented processing. These insights are verified through a simulation comparison of five cellular manufacturing systems with a functional layout system in which optimal lot sizes, low move times and a part family-oriented scheduling rule are used.

Suggested Citation

  • Nallan C. Suresh & Jack R. Meredith, 1994. "Coping with the Loss of Pooling Synergy in Cellular Manufacturing Systems," Management Science, INFORMS, vol. 40(4), pages 466-483, April.
    • Handle: RePEc:inm:ormnsc:v:40:y:1994:i:4:p:466-483
    DOI: 10.1287/mnsc.40.4.466
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    1. repec:dgr:rugsom:95a45 is not listed on IDEAS
    2. D'Angelo, Andrea & Gastaldi, Massimo & Levialdi, Nathan, 2000. "Production variability and shop configuration: An experimental analysis," International Journal of Production Economics, Elsevier, vol. 68(1), pages 43-57, October.
    3. Olorunniwo, Festus & Udo, Godwin, 2002. "The impact of management and employees on cellular manufacturing implementation," International Journal of Production Economics, Elsevier, vol. 76(1), pages 27-38, March.
    4. Cao, Qidong & Patterson, J. Wayne & Bai, Xue, 2005. "Reexamination of processing time uncertainty," European Journal of Operational Research, Elsevier, vol. 164(1), pages 185-194, July.
    5. Hamister, James W. & Suresh, Nallan C., 2008. "The impact of pricing policy on sales variability in a supermarket retail context," International Journal of Production Economics, Elsevier, vol. 111(2), pages 441-455, February.
    6. Shambu, Girish & Suresh, Nallan C., 2000. "Performance of hybrid cellular manufacturing systems: A computer simulation investigation," European Journal of Operational Research, Elsevier, vol. 120(2), pages 436-458, January.
    7. Jensen, John B., 2000. "The impact of resource flexibility and staffing decisions on cellular and departmental shop performance," European Journal of Operational Research, Elsevier, vol. 127(2), pages 279-296, December.
    8. Molleman, Eric & Slomp, Jannes & Rolefes, Samantha, 2002. "The evolution of a cellular manufacturing system - a longitudinal case study," International Journal of Production Economics, Elsevier, vol. 75(3), pages 305-322, February.
    9. Riezebos, J. & Gaalman, G.J.C., 1995. "Relations between cells in cellular manufacturing," Research Report 95A45, University of Groningen, Research Institute SOM (Systems, Organisations and Management).
    10. Nomden, Gert & van der Zee, Durk-Jouke, 2008. "Virtual cellular manufacturing: Configuring routing flexibility," International Journal of Production Economics, Elsevier, vol. 112(1), pages 439-451, March.
    11. Wenhui Zhou & Dongmei Wang & Weixiang Huang & Pengfei Guo, 2021. "To Pool or Not to Pool? The Effect of Loss Aversion on Queue Configurations," Production and Operations Management, Production and Operations Management Society, vol. 30(11), pages 4258-4272, November.
    12. Kannan, Vijay R. & Palocsay, Susan W., 1999. "Cellular vs process layouts: an analytic investigation of the impact of learning on shop performance," Omega, Elsevier, vol. 27(5), pages 583-592, October.
    13. Manning, William & Jensen, John, 2006. "Evaluating the shop-wide performance effect of pooling synergy with analytical models," European Journal of Operational Research, Elsevier, vol. 175(2), pages 1009-1020, December.
    14. van der Vaart, Taco & Wijngaard, Jacob, 2007. "The contribution of focus in collaborative planning for make-to-order production situation with large set-up times," International Journal of Production Economics, Elsevier, vol. 108(1-2), pages 436-443, July.
    15. Saif Benjaafar & Sunderesh S. Heragu & Shahrukh A. Irani, 2002. "Next Generation Factory Layouts: Research Challenges and Recent Progress," Interfaces, INFORMS, vol. 32(6), pages 58-76, December.
    16. Mor Armony & Guillaume Roels & Hummy Song, 2021. "Pooling Queues with Strategic Servers: The Effects of Customer Ownership," Operations Research, INFORMS, vol. 69(1), pages 13-29, January.
    17. Kannan, V. R. & Ghosh, S., 1995. "Using dynamic cellular manufacturing to simplify scheduling in cell based production systems," Omega, Elsevier, vol. 23(4), pages 443-452, August.
    18. Shafer, S. M. & Meredith, J. R. & Marsh, R. F., 1995. "A taxonomy for alternative equipment groupings in batch environments," Omega, Elsevier, vol. 23(4), pages 361-376, August.

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