BINARY ORDERING ALGORITHM (RANK ORDER CLUSTERING)

Block Diagonal Structure Provides an efficient routine for taking an arbitrary 0 1 machine-part matrix and reordering the machine rows and part columns to obtain a nearly block diagonal structure
Machine A B C D E F 1 1 1 2 1 1 3 1 1 Part 4 5 6 7 8

1 1

1 1

1 1 1 1 1 1

Example of dense block diagonal matrix Block diagonal means that a machinepart matrix can be partitioned such that the main diagonal boxes contain mainly 1s and less number of 0s but the off-diagonal boxes contain only 0s. To get G X G partitioned matrix, we have to draw (G 1) horizontal lines and (G 1) vertical lines. The on-diagonal boxes show the natural group for the manufacturing plant However, groups may not be totally independent

Machine A B C D E F

1 1 1

2 1 1

3 1 1 1

Part 4

1 1

1 1

1 1

1 1 1

1 1

Example for groups not independent Elements C3 and D7 fall outside the diagonal blocks. These are called exceptional elements Alternatives to handle exceptional elements Try to redesign parts 3 and 7 so as not to require machines C and D respectively Acquire extra machines of type C and D, placing a C in groups 1 and 2 and a D in groups 2 and 3 (Utilisation should be considered) Route parts 3 and 7 to two groups Combine these nearly independent groups into one large group Binary Ordering Algorithm Consider the rows and columns as binary strings To get block diagonal form, the similar rows should be brought together and similarly similar columns A row is a binary number, then similar rows have similar values; similarly we can envision columns That is, we can reorder rows or columns in the descending order of their binary value

Algorithm Step 1. For row m = 1,2M, compute the decimal equivalent of binary string
P

cm

cm = 2 P p a pm ; a pm = 0 or 1
p =1

where P number of parts (columns), p index for column Reorder the rows in decreasing order of c m . In case of tie, keep the original order Step 2. Compute the decimal equivalent of binary string

rp corresponding to column p
r p = 2 M m a pm ; a pm = 0 or 1
Reorder the columns in decreasing order rp . In case of tie, keep the original order Step 3. If the new part-machine matrix is unchanged, then stop, else go to step 1.

Example
Machine A B C D E F 1 1 2 1 1 3 1 1 1 1 1 1 1 1 Part 4 5 1 6 7 8 1 1 1 1 1 1

Solution Step 1.
Machine A B C D E F
P p

1 1

2 1 1

3 1 1 1

Part 4 5 1

8 1

1 1 1 1 8 1 4

1 1 1 2 1

32 16 2 Order of rows A, F, C, E, B and D Step 2. Machine A F C E B D Value 1 1 1 2 1 1 1 3 Part 4 5 1 1 1 1 5

1 128

1 64

Value 200 17 102 17 54 200

2 M m
32 16 8 4 2 1

1 1 1 14

1 1

1 1 1 1 3

48

56

48

12

12

Order of columns 2, 1, 5, 3, 6, 7, 4 and 8

Step 1.
Machine A F C E B D 2 1 1 1 1 1 1 5 1 1 Part 3 6 7 4 8 Value 224 224 156 30 17 3

1 1 1 64 32 16

1 1

1 1

1 1 2 1 1 1

P p

128

Ending orderings are not unique for a given data set Different starting orderings may yield different ending orderings It provides starting point for most of the grouping procedure