Implementing Cellular

Manufacturing
At Pakistan Spring & Engineering Co. (Ltd.)
 Group Members

• Nabeel Safdar 2008-IME-91

• Khawaja Ahsan ul Haq 2008-IME-69
• Hassan Habib 2008-IME-72
• Hafiz Faizan 2008-IME-46
• Muhammad Raza 2008-IME-95
 Why it is done?
• To shorten lead times
• To reduce inventory
• To improve quality
• To simplify Production scheduling
• To reduce setup time
 Prerequisites

 Producing according to Takt Time (Line Balancing)

 Planning of layout must be feasible in order to cater
the cells made
 Pull system has to be integrated to the parts that are
to be arranged in a cell (Kanban)
 Individual Changeover times of machines must be
reduced to a minimum in order to benefit from
cellular manufacturing
 Step 1

Data Collection
 Parts

• Body C CD 70 cc
• Seat Spring
• Mouth Collar
• Plate Baffle
• Main Plate for Honda CG 125
• Suzuki pickup steering spoke
 Our Parts
Body C of CD 70 cc
 Our Parts
Seat Spring of Honda CD 70 cc
 Our Parts
Mouth Collar of Honda CD 70 cc
 Our Parts
Plate Baffle of Honda CD 70 cc
 Our Parts
Main Plate of Honda CG 125
 Our Parts
Suzuki pickup steering spoke
 Operations
Machine names with processes

Blanking on shearing press

Blanking on power press

1st Draw on Hydraulic Press

2nd Draw on Hydraulic Press

Cutting on Lathe

Facing on Lathe
Trimming on Power Press

Bending on Power Press

Punching on Pneumatic Press

Piercing on Power Press

 Step 2

Sortation of process routings

 Parts
Monthly
Producti
Part Code Part Name Routing on

A. Body C CD 70 cc 2-3-4-6-7 2000

B. Seat Spring 2-3-6-7 2500
C. Mouth Collar 5-8-9 5000
D. Plate Baffle 2-3-4-7 3000
E. Main Plate for Honda CG 125 1-9-8 2500
F. Suzuki pickup steering spoke 1-9-10-8 2500
 Operations
Operation Machine names with processes
Code
1 Blanking on shearing press
2 Blanking on power press
3
1st Draw on Hydraulic Press
4 2nd Draw on Hydraulic Press
5 Cutting on Lathe
6 Facing on Lathe
7 Trimming on Power Press
8 Bending on Power Press
9 Punching on Pneumatic Press
10 Piercing on Power Press
 Step 3

Process Flow Analysis (PFA)

Chart/ Part-Machine incident
Matrix
Part machine Incident Matrix

Operations Parts
A B C D E F
1 I I
2 I I I
3 I I I
4 I I
5 I
6 I I
7 I I I I
8 I I I
9 I I I
10
 Step 4

Cluster Analysis
Part I – Rank Order Clustering
 1st Iteration
Parts
Operations 32 16 8 4 2 1 Decimal Equivalent Rank
A B C D E F
1 I I 3 9
2 I I I 52 1
3 I I I 52 2
4 I I 36 5
5 I 8 8
6 I I 48 4
7 I I I I 52 3
8 I I I 11 6
9 I I I 11 7
10 1 10
 1st Iteration
Parts
Operations 32 16 8 4 2 1

A B C D E F
2 I I I
3 I I I
7 I I I
6 I I
4 I I
8 I I I
9 I I I
5 I
1 I I
10 I
 2nd Iteration
Operations Parts
A B C D E F
2 I I I 512

3 I I I 256

7 I I I 128

6 I I 64

4 I I 32

8 I I I 16

9 I I I 8

5 I 4

1 I I 2

10 I 1

Decimal 992 960 28 928 26 27

Equivalent

Rank 1 2 4 3 6 5
 2nd Iteration
Parts
Operations 32 16 8 4 2 1 Decimal Equivalent Rank
A B D C F E
2 I I I 56 1
3 I I I 56 2
7 I I I 56 3
6 I I 48 4
4 I I 40 5
8 I I I 7 6
9 I I I 7 7
5 I 4 8
1 I I 3 9
10 I 2 10
 Step 4

Cluster Analysis
Hollier Method 2
 From - To
Operation
To Machine names with processes From
Code

0 1 Blanking on shearing press 2500+2500

0 2 Blanking on power press 2000+2500+3000
2000+2500+3000 3 2000+2500+3000
1st Draw on Hydraulic Press
2000+3000 4 2nd Draw on Hydraulic Press 2000+3000
0 5 Cutting on Lathe 5000
2000+2500 6 Facing on Lathe 2000+2500
2000+3000+2500 7 Trimming on Power Press 0
5000+2500+2500 8 Bending on Power Press 5000
5000+2500+2500 9 Punching on Pneumatic Press 2500+2500
2500 10 Piercing on Power Press 2500
 From - To
Cluster 1

To
From/To
2 3 4 6 7 From sums Ratio
2 0 7500 0 0 0 7500 ∞
From 3 0 0 5000 2500 0 7500 1

4 0 0 0 2000 3000 5000 1

6 0 0 0 0 4500 4500 1

7 0 0 0 0 0 0

To Sums 0 7500 5000 5000 7500 24500

 Network Diagram

2500

7500 7500 5000 2000 4500

2 3 4 6 7
7500

3000
 Performance Measures

 Percentage in sequence moves = 19000/24500*100 = 77.5%

 Percentage By-Passing Moves = 5500/24500*100 = 22.5 %

 Percentage Back Tracking Moves = 0/24500*100 =0%

 From-To
Cluster 2

    To    
From  From/To 
1 5 8 9 10
  sums Ratio
1 0 0 0 5000 0 7500 ∞
From 5 0 0 5000 0 0 7500 ∞

8 0 0 0 5000 0 5000 0.5

9 0 0 2500 0 2500 4500 0.5

10 0 0 2500 0 0 0 1

To Sums 0 0 10000 10000 2500 22500  

 Network Diagram

2500
5000
2500

0 0 2500 5000 5000

5000
1 5 10 8 9

5000
5000
5000
 Performance Measures

 Percentage in sequence moves = 7500/22500*100 = 33.33%

 Percentage By-Passing Moves = 10000/22500*100= 44.44 %

 Percentage Back Tracking Moves = 5000/22500*100 = 22.22 %

 Conclusions
 2 cells are made comprising of 5 machines

 The cells are type II M (Group machine cell with manual handling)

 For 1st cluster U shaped layout is suggested (As there are in sequence moves)

 For 2nd cluster rectangular layout is suggested (As there are back track moves)

 There is a drastic reduction in the “transportation” and “motion” waste