Capability-based virtual cellular manufacturing systems formation in dual-resource constrained settings using Tabu Search

► A multi-objective mathematical-model is developed to form CBVCMSs with RE approach. ► The system is developed in DRC settings by considering workers with multi-level and heterogeneous flexibility. ► A multi-objective TS is designed to form CBVCMSs so that parts, machines, and workers assigned to cells simultaneously. ► A new criterion named as SCU is defined to compare the developed CBVCMSs and CMSs. ► The priority of the developed CBVCMSs in compare to the original CMSs is illustrated by the calculated SCUs. Formation of Virtual Cellular Manufacturing Systems (VCMSs), as one of the main applications of Group Technology (GT), by presentation of unique and shared capability boundaries of machine tools through defining Resource Elements (REs) creates a good solution for Capability-Based VCMSs (CBVCMSs), which increases opportunities to create systems with more efficient utilizations. Considering workers as the second important resources in Dual-Resource Constraint (DRC) settings makes this problem more serious and critical to research because, in reality, jobs cannot be processed if workers, machines, or both are not available. This paper attempts to form CBVCMSs with DRC settings using a multi-objective mathematical model with a Goal Programming (GP) approach. Using the developed model, parts, machines, and workers are grouped and assigned to the generated virtual cells at the same time. The proposed model is solved through a multi-objective Tabu Search (TS) algorithm to find optimum or near-to-optimum solutions. The validity of the developed model is illustrated by two numerical examples taken from the literature and evaluated through comparing the performance of the CBVCMSs and the original classical CMSs in the System Capacity Utilization (SCU) point of view.