A genetic algorithm for multiple objective dealing with exceptional elements in cellular manufacturing

Cellular Manufacturing (CM) is an important application of Group Technology (GT) in which families of parts are produced in manufacturing cells or a group of various machines, which are physically close together and can entirely process a part family. The manufacturing system established based on such an idea is called Cellular Manufacturing System (CMS). A major problem associated with many CMSs is the existence of Exceptional Elements (EEs), i.e. bottleneck machines and exceptional parts. These are machines/parts that cannot be exclusively assigned to a machine cell/part family. In this paper a new model is presented for dealing with the EEs in the form of a Multi-objective Optimization Problem (MOP). This model aims to minimize: (1) intercellular parts movements, (2) total cost needed for machine duplication and part subcontracting, (3) the system's under-utilization, and (4) deviations among the cells' utilization. Attaining an ideal solution, which is optimal to all of the objectives is prohibited, as they conflict with each other. Hence, a Multi-Objective Genetic Algorithm (MOGA) is developed to provide the decision-maker with a set of non-dominated or Pareto-optimal solutions. Comparisons between the developed MOGA and three other MOGAs show its viability in three performance aspects, namely: quality, diversity and CPU time.