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Contents
1.
2.
3.
4.
Introduction
Background and History
Components and Implementation
Knowledge Check
Introduction
Cellular Manufacturing is a workplace design reflecting
concepts of lean manufacturing. Waste is reduced and
resources are combined to provide maximum efficiency.
Cellular manufacturing, sometimes called cellular or
cell production, is the idea of manufacturing an entire
product or small product line in the same work cell.
Process and product changeovers are minimized and
part operations are linked to help reduce waste and
eliminate overproduction.
Basic Layouts
There are three basic types of layouts:
Process
Product
Fixed-position
Fixed-position
Flexible and Mixed-Model manufacturing systems
Cellular
Process Layout
A layout that groups similar activities together in
departments of work centers according to process or
functions that they perform.
Advantages
Deep knowledge of the process
Common tooling and fixtures
Most Flexible -- can produce many different part types
Disadvantages
Product Layout
A facility layout that arranges activities in a line
according to the sequence of operations that need to
be performed to assemble a product, while minimizing
material handling costs.
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Product Layout
Layout corresponds to the sequence of operations, smooth
and logical flow lines result
Work from one process is fed directly into the next, small inprocess inventories result
Total production time per unit is short
Machines are located as to minimize distances between
consecutive operations, material handling is reduced
Little skill is usually required by operators at the production
line; hence, training is simple, short and inexpensive
Simple production planning and control systems are possible
Less space is occupied by work in transit and for temporary
storage
Lower variable cost per unit
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Product Layout
Advantages
Disadvantages
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Hybrid Layouts
Flexible & Mixed-Model
High level of complexity
Mathematically intensive
Cellular
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Cellular Layouts
The cellular approach is to organize the entire
manufacturing process for particular or similar products
into one group of team members and machines known
as a "Cell".
These "cells" are arranged in a U-shaped layout to
easily facilitate a variety of operations.
Parts or assemblies move one at a time (or in small
batch sizes).
The parts are handed off from operation to operation
without opportunity to build up between operations.
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Cellular Layouts
Fast setup and quick changeovers are essential to
Cellular Manufacturing systems since production runs
are shorter.
Setup reduction principles are used to achieve one
piece flow and mixed model synchronization.
All cells concentrate on eliminating waste.
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Functional
Many
Cellular
Few
Travel Distance
More
Less
Routings
Complex
Simple
Route Structure
Variable
Fixed
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Functional
Fragmented
Cellular
Focused
Problem Solving
Difficult
Team
Quality
Erratic
Consistent
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Functional
Large
Cellular
Small
More than 10
Less than 10
Make to Stock
Make to Order
Complex
Simple
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Functional
Cellular
Weeks
Hours
Weeks-Months
Days
Erratic
Consistent
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Creating Cells
First, define the cells by the following criteria:
Processes required
Part numbers and attributes
Market segments / customers
Degree of automation
Good intuition
Careful study
Group Technology (GT)
Production Flow Analysis (PFA)
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Creating Cells
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Creating Cells
Team selection is crucial
Identify important skills needed such as teamwork and
leadership skills
Create a process map
Develop a checklist for selecting members
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Part Families
Part families with
similarity in
manufacturing process
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Visual Inspection
Easiest and least expensive method
Classification takes place by looking at their
photographs or physical parts
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Supplementary
Code
Secondary
Code
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Group Analysis
The flows in each of the individual shops (identified by
FFA) are analyzed.
Operation sequences of the parts that are being
produced in a particular shop are analyzed to identify
manufacturing cells.
Loads are calculated for each part family to obtain the
equipment requirements for each cell
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Group Analysis
Essentially, while forming and rearranging the PFA
matrix we were performing Group Analysis.
Those same algorithms are also employed in PFA
activities other than Group Analysis (namely CFA, FFA
etc..)
Choice of algorithm or technique that is best suited is,
for the most part, a problem specific issue
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Line Analysis
A linear or U-layout is designed for the machines
assigned to each cell.
The routings for each part assigned to the cell and the
frequency of use of each routing are used to develop a
cell for:
Efficient transport
Minimum material handling and travel by operators.
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Tooling Analysis
A Tooling Analysis helps to schedule the cell by
identifying families of parts with similar operation
sequences, tooling and setups.
It seeks to sequence parts on each machine to
sequence all the machines in the cell to reduce setup
times and batch sizes.
This increases available machine capacity on
bottleneck work canters in the cell.
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PFA: Assumptions
Each component is equally important in terms of cost
Lot size & its associated cost are not directly related to
grouping procedure
Routing is assumed to be optimal
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PFA: Advantages
Reduces flow distances
Better suited to JIT and pull manufacturing as the
overall flow is much straighter
Simple and Easy to implement
Experience: Lots of Research and Background and
support software
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PFA: Weakness
PFA is suitable mostly for small-sized applications, but
it has difficulties coping with some large cell formation
problems when the Machine-Part Matrix becomes more
complex because of problem size
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Line Balancing
Line balancing a important part in Cellular System
Improper balance leads to several effects
Excess Inventory
Idle Equipment
Idle People
Individual Frustration
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Knowledge Check
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apply)
1. Process
2. Product
3. Fixed-position
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(Mark
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Congratulations!!!
You have completed the course.
Visit Superfactory (www.superfactory.com) for more
information on manufacturing excellence.
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