Design, Analysis, and Performance evaluation of Cellular Manufacturing System for Conventional Manufacturing Factory : A case of Addis Machine Spare Parts Manufacturing Industry

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Addis Ababa University


This thesis assessed the performance problems at the Addis Machine Spare Part Conventional Manufacturing Factory (ASPCMF) under the Ethio Engineering Group (EEG). The case factory has been faced a number of manufacturing system challneges according to the data collected from the operations department of the factory. After the analysis performed based on the existing layout evaluation, problems identified were higher idle time of machines and longer travel distances of parts that lead to lower performance. From the study of the previous performance survey done in 2021, the overall performance recorded was 38.03%. After analyzed the existing layout performance using FlexSim software 31.8% performance recorded. This lower performance identified necessitates the requirement to design a new layout and analyzed the performance based on machine utilization and travel distance of parts. Therefore, the purpose to assess the existing manufacturing system based on machine utilization and travel distance of parts led to design, analysis, and evaluate the performance by proposing a cellular manufacturing system. In the design work a 22 part family was created using the Optiz coding system, which was based on hybrid coding system. A method of machine grouping in an incident matrix was developed to form 20 cells. The rank Order clustering algorithm was used to cluster parts and machines within the cell. This minimized 45 duplicated machines in bottlenecks, while increasing the machine utilization of 43 machines in the cluster formed. The designed cell in the cluster was evaluated through grouping efficacy (GE) of parts allotted in cells to achieve optimal effectiveness in cell utilization which was 91% cell efficiency. The CRAFT algorithm used to identify the part flow within the department and the effectiveness of machine arrangement analyzed based on part travel distance that was reduced into 1,425 m from the existing layout 2,236.10 m which increased floor space available so that, an improved layout was proposed. The analysis was performed to evaluate the designed cell, the performance simulation shows that 88.37% of the proposed cellular layout demonstrates significant enhancemenent compared to the existing layout, which was only 31.8 %. The performance simulation was conducted using FlexSim software. Finally,the individual machine utilization percentage was determined and compared between the proposed layout and the existing layout.



Incident matrix, idle time, Grouping Efficacy, Rank order clustering algorithm, CRAFT algorithm, FlexSim