Maximizing Group Efficacy for the Generalized Cell Formation Problem Using Route Rank Index and Genetic Algorithm

Cell formation plays a crucial role in the development of cellular manufacturing systems (CMS). Previous studies in this field have typically assumed that each part is associated with a single process plan. However, incorporating alternative routes offers additional flexibility in CMS design. This paper addresses the cell formation problem by considering alternative routes and presents a two-stage approach to address this problem. In the first stage, a Route Rank Index (RRI) is developed based on a correlation matrix to select the optimal alternative route for each part. Subsequently, a Genetic Algorithm (GA) is employed in the second stage to form part families and machine cells. The proposed approach's computational performance is evaluated using a set of generalized group technology datasets found in the existing literature. The results demonstrate that the proposed approach is highly effective and efficient when it comes to addressing the cell formation problem involving alternative routes. The ramifications of these findings in practice are substantial. Our suggested approach demonstrates its resilience and adaptability by achieving comparable or better grouping results across a wide variety of benchmark datasets. This shows the method can be used in a wide range of practical situations, including those involving matrices of varying sizes and shapes. The theoretical knowledge base on part-machine grouping strategies benefits from the comparison study. By comparing the results of our suggested method to those of well-known heuristics, we shed light on its benefits and drawbacks. Index Terms— Route Rank Index; Alternative Routes; Cellular Manufacturing System; Cell Formation; Genetic Algorithm.