Direct Clustering Algorithm (DCA) – Procedure with

example
Example 01
Step 01: order the rows and columns Step 02: Sort the columns
Beginning with the first row of the matrix, shift to the left of the
a) Sum the 1s in each column and in each row of matrix all columns having a 1 in the first row. Continue the
the machine-part incidence matrix. process row by row until no further opportunity exists for
shifting columns.

Machines Machines # of Machines Machines # of

Parts 1s Parts 1s

M01 M02 M03 M04 M05 M05 M04 M02 M03 M01

P01 1 1 2 P03 1 1 1 3

P02 1 1 P06 1 1 2

P03 1 1 1 3 P04 1 1 2

P04 1 1 2 P01 1 1 2

P05 1 1 P05 1 1

P06 1 1 2 P02 1 1

# of 1s 3 2 2 2 2 # of 1s 2 2 2 2 3

b) Order rows (top to bottom) in descending order Step 03: Sort the rows
of the number of 1s in the rows, break the tie in Column by column, beginning with the leftmost column, shift
descending numerical sequence. (large index to rows upward when opportunities exist to form blocks of 1s
small index)
Machines Machines # of Machines Machines # of
Parts 1s Parts 1s

M01 M02 M03 M04 M05 M05 M04 M02 M03 M01

P03 1 1 1 3 P03 1 1 1 3

P06 1 1 2 P06 1 1 2

P04 1 1 2 P05 1 1

P01 1 1 2 P04 1 1 2

P05 1 1 P01 1 1 2

P02 1 1 P02 1 1

# of 1s 3 2 2 2 2 # of 1s 2 2 2 2 3

c) Order the columns (left to right, in ascending Step 04: Form cells
order of the # of 1s in each); tie (descending Look for opportunities to form cells such that all processing for
numerical sequence) each part occurs in a single cell.

Machines Machines # of Machines Machines # of

Parts 1s Parts 1s

M05 M04 M03 M02 M01 M05 M04 M02 M03 M01

P03 1 1 1 3 P03 1 1 1 3

P06 1 1 2 P06 1 1 2

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 P04 1 1 2 P05 1 1

P01 1 1 2 P04 1 1 2

P05 1 1 P01 1 1 2

P02 1 1 P02 1 1

# of 1s 2 2 2 2 3 # of 1s 2 2 2 2 3

Interpreteation of Final Part-Machine Incidence Matrix

Group No. Machine Cluster Component Family
1 Cell M05, M04, and M02 Part Family P03, P06, and P05
2 Cell M03, and M01 Part Family P04, P01, and P02

Direct Clustering Algorithm (DCA) – Procedure with

example
Example 02
Step 01: order the rows and columns Step 02: Sort the columns
Beginning with the first row of the matrix, shift to the left of
a) Sum the 1s in each column and in each row of the the matrix all columns having a 1 in the first row. Continue the
machine-part incidence matrix. process row by row until no further opportunity exists for
shifting columns.

Machines Machines # of Machines Machines # of

Parts 1s Parts 1s

M01 M02 M03 M04 M05 M06 M07 M06 M05 M04 M03 M07 M02 M01

P01 1 1 1 3 P05 1 1 1 1       4

P02 1 1 2 P03     1   1 1 1 4

P03 1 1 1 1 4 P04 1     1     1 3
P04 1 1 1 3 P01     1   1 1   3

P05 1 1 1 1 4 P02   1   1       2

# of 1s 2 2 3 3 2 2 2   # of 1s 2 2 3 3 2 2 2

b) Order rows (top to bottom) in descending order Step 03: Sort the rows
of the number of 1s in the rows, break the tie in Column by column, beginning with the leftmost column, shift
descending numerical sequence. (large index to rows upward when opportunities exist to form blocks of 1s
small index)
Machines Machines # of Machines Machines # of
Parts 1s Parts 1s

M01 M02 M03 M04 M05 M06 M07 M06 M05 M04 M03 M07 M02 M01

P05     1 1 1 1   4 P05 1 1 1 1       4

P03 1 1   1     1 4 P04 1     1     1 3

P04 1   1     1   3 P03     1   1 1 1 4

P01   1   1     1 3 P01     1   1 1   3

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 P02     1   1     2 P02   1   1       2

# of 1s 2 2 3 3 2 2 2   # of 1s 2 2 3 3 2 2 2  

c) Order the columns (left to right, in ascending Step 04: Form cells
order of the # of 1s in each); tie (descending Look for opportunities to form cells such that all processing for
numerical sequence) each part occurs in a single cell.

Machines Machines # of Machines Machines # of

Parts 1s Parts 1s

M07 M06 M05 M02 M01 M04 M03 M06 M05 M04 M03 M07 M02 M01

P03   1 1     1 1 4 P05 1 1 1 1       4

P06 1     1 1 1   4 P04 1     1     1 3

P04   1     1   1 3 P03     1   1 1 1 4

P01 1     1   1   3 P01     1   1 1   3

P05     1       1 2 P02   1   1       2

# of 1s 2 2 2 2 2 3 3 # of 1s 2 2 3 3 2 2 2

Interpreteation of Final Part-Machine Incidence Matrix

Group No. Machine Cluster Component Family
1 Cell M06, M05, M04, and M03 Part Family P05, and P04
2 Cell M07, M02, and M01 Part Family P03, P01, and P02

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