Abstract
This paper presents a design methodology and a genetic algorithm-based approach for redesign of a manufacturing system for a small steel pre-fabricated building manufacturer. Through the application of celular manufacturing principles, we discuss the application of the design methodology that takes a topdown approach to determine system needs and a bottom-up integrated design approach to develop the configurations of the manufacturing system. The integrated design approach uses a genetic algorithm and an AutoCAD interface to minimize the inter and intra cell material movements during cell formation. A selected set of solutions obtained are further analysed using discrete event modelling and simulation. The final results presented indicate a substantial improvement in overall performance compared to the original layout. The company has implemented a modified version of the final solution and has achieved the significant improvements in material handling and overall productivity.