1. ZAINAL RASYID MAHAYUDDIN
NUR AFIQAH KHAIRUDDIN

2. Aim and objectives of the research
Research methodology
Stage I - Data collection
Stage II – Classification development
Stage III – Prototype development
Stage IV – Testing and Validation

3. CELLULAR MANUFACTURING - application
of group technology in manufacturing
Processing collection of similar parts (part
families) on dedicated clusters of
machines or manufacturing processes
(cells).
Source - Steve Ah
kioon, 2009

4.  Low production rate
Cellular manufacturing problem
 Configuration of cells in layout
designing layout in production floor
 Issues in solution of cellular manufacturing problems
 require a lot experience/ knowledge
Time consuming
Costly activities
 Tool available simulation and modeling

5. .
Aim : To investigate the cladistic technique approach to
classify cellular manufacturing problems
1. To classify problems in cellular manufacturing using
cladistics technique
2. Develop a prototype and validate cladistics using
prototype

6. RESEARCH METHODOLOGY

7. Collecting data samples to thoroughly
understand problems and causes of
problems obtained.
The information are needed during
classification phase

8. Productivity
7%
Performance
26%
Layout
10%
Cost
12%
Quality
2%
Other
43%
Problems
performance in
cell
8%
Efficiency of cell
layout
11%
efficiency of cell
formation
65%
efficiency of
utilization
machine
4%
efficiency of
workers
12%
Performance
EXAMPLE PROBLEMS

9. “Cladistics is a method for systematically
organizing knowledge about a population
of entities. It is a process for studying
diversity and attempting to identify and
understand laws and relationships that
explain the evolution and existence of
the variety of groups”
Source:Tsinopoulos
and McCarthy
(2000)

10. Selecting taxa
Identify characteristics
of the cladogram
Determine the states
of characteristics
Generating cladogram
by software

11. FACTORS States Performance Measure
1 ecxessive scrap 0 Absence
1 Scrap rate
2 Rework 0 Absence
1 Rework cost
3 Lack of coordination 0 Absence
(labour) 1 Labor efficiency
4 Flexibility of worker 0 Absence
1 Workload
5 Efficiency training 0 Absence
for workers 1 Labor efficiency
6 Productivity low 0 Absence
1 Production volume
7 Lack of product 0 Absence
understanding 1 Production volume
8 Excessive inventories 0 Absence
1 WIP Inventory
9 High machine 0 Absence
breakdown 1 maintenance cost
10 Machine utilization 0 Absence
1 Machine efficiency
11 No. of machines 0 Absence
more than no of worker 1 Labor efficiency
12 High equipment cost 0 Absence
1 Total cost
13 High allocation of machine cost 0 Absence
1 Total cost
14 Setup time 0 Absence
1 Setup cost
15 Total delay time 0 Absence
1 Backorder cost (delay delivery parts)
16 Bottleneck/ total waiting 0 Absence
1 Delivery time performance
17 Lead time 0 Absence
1 Production volume/ produstion rate
18 high setup cost 0 Absence
1 Total cost
19 high operation cost 0 Absence
1 Total cost
20 high reconfiguration cost 0 Absence
1 Total cost
21 High intercellular movement distance 0 Absence
1 material handling cost
22 High intracellular movemnet distance 0 Absence
1 material handling cost
23 Space limitation 0 Absence
1 intra/inter cellular movement cost
24 Machine capacity 0 Absence
1 Machine efficiency
25 Operation time 0 Absence
1 Production volume/rate

12. PROBLEM FACTORS / CHARACTERS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1 Low productivity 1 1 1 0 0 1 1 0 1 0 0 0 0 1 1 1 1 0 0 0 0 0 0 1 1
2 Poor quality 1 1 1 0 0 0 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3 Poor performance in cell 0 0 1 1 0 1 0 0 1 1 1 0 0 0 1 1 1 0 0 0 1 1 1 1 1
4 Poor efficiency in cell layout 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 1 0 0 0 1 1 1 0 1
5 Poor efficiency of cell formation 0 1 1 1 0 0 1 0 0 0 0 1 1 1 1 1 1 1 1 0 1 1 1 0 1
6 Low efficiency of utilization machine 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 1 1
7 Low efficiency of workers 0 1 0 1 1 1 1 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 Total intercellular & intracellular movement distance increase 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0 0 0 1 1 1 0 0
9 excessice quantity of operators 0 1 1 1 1 0 1 0 0 0 0 1 1 0 0 1 0 1 1 1 1 1 1 0 0
10 Total material handling cost increase 1 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 1 1 0 0
11 High Holding inventory cost 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 1
12 Backorder increase 0 0 0 0 0 0 0 1 1 0 0 0 0 0 1 1 0 0 0 0 0 0 0 0 0
13 High reconfiguration cost 0 1 0 0 0 0 0 1 0 0 1 1 0 0 0 0 0 0 0 1 0 0 0 0 0
14 High investment cost 1 1 1 0 1 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
15 High machine setup cost 1 1 0 1 0 1 1 0 0 1 0 0 0 0 1 0 1 1 1 1 0 0 0 0 0
16 High WIP 0 1 1 1 1 1 0 1 1 1 0 0 0 0 1 1 1 0 0 0 1 1 0 1 1
17 Low performance of movement flow 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 1 1 1 1 1 1
18 Poor scheduling system 0 0 1 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 1 0 0 0
19 Unbalanced workload in cell 0 1 1 1 1 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0
20 Irrelevant relation between routing flexibility and correspondent cost0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1 1 0 0 0
21 High space requirement 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0 0 0 0 1 1 0 1 0
22 Changes make-to-stock system to make-to-order system 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0

13. Figure 4. Problems Classification Cladogram
Figure 5. Evolution Trend

14. Problems in cellular
manufacturing
Problems classification
through cladistics
technique
Templates and Modules
Phase I I
Physical
elements
Attributes and
functions
Performance
measure
element
Simulation Panel
yes
Low fidelity prototype
User interface
development using VBA
Proof of concept
User
validation
no
Phase II
Prototype
development

15. Simulation Template
• Performance Measure :
Lead Time
• Series Time Chart
• Expression Function :
TAVG(Entity.TotalTime)
• Performance Measure:
Waiting time/Bottleneck
• Histogram
• Expression Function
• TAVG(Entity1.WaitTime)
• TAVG
(Buffer1.Queue.WaitingTim
e)
• Expression Function :
EntitiesWIP(Entities)
• Series Time chart
• Expression Function:
• EntitiesOut(Entity 1)
• Series time chart

16. Model Building
Performance Measure

17. Two modes of exercises :
Do exercise manually using ARENA software
Do exercise using prototype
Objective : To compare model time building
and to prove usefulness of prototype

18. Mode A : Building model manually
First Student Second Student Third Student Time Average (min)
Exercise 1 2.13 10.37 9.21 7.23
Exercise 2 i 10.27 15.47 11.21 12.31
Exercise 2 ii 6.58
Exercise 2 iii
Exercise 3 i 3.19 5.55 6.02 4.9
Exercise 3 ii 4.26
Exercise 3 iii
Scale Evaluation %
Exercise 1 4 3 2 3 60
Exercise 2 i 3 2 4 3 60
Exercise 2 ii 2 2 2 2 40
Exercise 2 iii 2 2 3 2.33 46.6
Exercise 3 i 4 3 3 2.33 67.6
Exercise 3 ii 3 2 2 2.33 46.6
Exercise 3 iii 3 2 2 2.33 46.6
Mode B : Building model using prototype
First Student Second
Student
Third Student Time Average (min)
Exercise 1 1.30 4.03 1.50 2.27
Exercise 2 i 4.47 5.34 5.21 5.03
Exercise 2 ii 6.58 1.34 5.29 4.4
Exercise 2 iii 00.30 00.30 1.04 0.54
Exercise 3 i 1.47 2.12 2.54 2.04
Exercise 3 ii 2.18 1.45 2.04 1.9
Exercise 3 iii 3.16 2.31 3.18 2.9
Scale Evaluation %
Exercise 1 4 5 5 4.33 86.6
Exercise 2 i 3 2 4 3.33 66.6
Exercise 2 ii 3 4 3 3 60
Exercise 2 iii 4 4 4 4.33 86.6
Exercise 3 i 4 4 5 4.67 93.4
Exercise 3 ii 5 5 3 4.67 93.4
Exercise 3 iii 4 4 4 4 80

19. First
student
Second
student
Third
student
Average Score
1)Duration involve in simulation and modeling
Never
0-6 months   
6-12 months
More than 12 months
2)User Experience in ARENA
Lesson in lecture  
Group project
Thesis project
Other than above 
3) Ease of use
The prototype is easy to
use
4 3 2 3
Guideline given is
understandable
3 2 3 2.67
Score percentage 56.67%
4)Usefulness of prototype
The prototype is very
useful in building the
model
5 4 3 4
The prototype can
reduce time model
building
5 4 3 4
Physical element can be
created easily
5 4 4 4.33
Performance measure
can be create easily
4 4 4 4
Performance measure
element is very useful for
modeling simulation
building
4 3 3 3.33
The prototype has a
potential to increase
simulation modeling
building
3 3 4 3.33
Average score
percentage
76.67%

20. Cladistic technique is used to classify the
problems according to factors identified
Problems can be solved by using
simulation tool based on classification
made
Reducing time of model development