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Chapter 3.1 Cellular Manufacturing PDF

The document discusses cellular manufacturing which organizes manufacturing processes for similar products into cells containing machines, tools, and workers to produce parts with minimal movement between operations. Cells are arranged to allow one-piece flow and quick changeovers, and empower employees to problem solve and manage their cell as an independent business unit. The benefits of cellular manufacturing include reduced setup times, material handling, and work-in-process inventory.

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Brix Aliado
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152 views24 pages

Chapter 3.1 Cellular Manufacturing PDF

The document discusses cellular manufacturing which organizes manufacturing processes for similar products into cells containing machines, tools, and workers to produce parts with minimal movement between operations. Cells are arranged to allow one-piece flow and quick changeovers, and empower employees to problem solve and manage their cell as an independent business unit. The benefits of cellular manufacturing include reduced setup times, material handling, and work-in-process inventory.

Uploaded by

Brix Aliado
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Cellular

Manufacturing

Adapted from:
Facilities Planning 3rd Ed. by Tompkins, White, Bozer, Tanchoco
Cellular Manufacturing: Introduction

 Product layout is the most efficient layout


 Many products are not made in volumes that
require a product layout
 Cellular manufacturing ( group technology)-
forms families of products that have common
production requirements
 Locate machines, people, jigs, fixtures, drawings,
measuring equipment, material handling
equipment together
Cellular Manufacturing: Introduction
 The cellular approach is to organize the entire
manufacturing process for a particular or similar
products into one group of team members and
machines known as cells
 These machines are arranged in U shaped layout
to 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
Cellular Manufacturing: Introduction

 Fast setup and quick changeovers are essential to


Cellular Manufacturing 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


Empowered Employees in Cellular
Manufacturing
 Goals and tracking charts are maintained and posted
 Problems are solved through daily cell meetings and
problem solving teams
 The inventory management system is a KANBAN Demand
Pull
 Cells are responsible for planning, scheduling and
expediting directly with vendors
 KANBAN is established and maintained with vendors
Advance Cell Manufacturing
 The cell operates like an independent business with total
responsibility for quality, manufacturing and delivery of
the product to the customer
 All cells have the resources with their organization to
accomplish their mission
 The requirements are known and goals are established.
 Cell members are flexible and work in teams to
accomplish their goals including continuous improvement.
Benefits of Cellular Manufacturing
 Common tooling required for many products ( fewer
setups)
 Tooling can be justified since many products require it.
( more volume when products are grouped)
 Minimized material handling
 Simple production schedule
 Short cycle time
 Low WIP
 Cross-training- employees operate several machines
 Minimized material handling costs-since no paperwork
is required and distance is small
Benefits of Cellular
Manufacturing
 Employees accept more
responsibility of
supervision (
scheduling of parts
within cell, scheduling
of vacations,
purchasing of material ,
managing a budget)
 Simple flow pattern
and reduced paperwork
Disadvantage of Cellular Manufacturing
 Lower equipment
utilization
 Increased setup costs
Family Formation
 Direct Clustering Algorithm ( DCA )– an approach use
in the selection of machine and part types for a particular
cell.
Step 1. Make a machine-part matrix and total the 1s in each
column and in each row.
Machine #
Part # 1 2 3 4 5 # of 1s
1 1 1 2
2 1 1
3 1 1 1 3
4 1 1 2
5 1 1
6 1 1 2
# of 1s 3 2 2 2 2
Family Formation
Step 2. Order the rows ( top to bottom) in descending order of the
number of 1s in the rows and order the columns ( left to rigth) in
ascending order of the number of 1s in columns. When ties exist,
break the ties in descending numerical sequence.

Machine #
Part # 5 4 3 2 1 # of 1s
3 1 1 1 3
6 1 1 2
4 1 1 2
1 1 1 2
5 1 1
2 1 1
# of 1s 2 2 2 2 3
Family Formation
Step 3. Sort the columns. Beginning with first row of the matrix, shift to
the left of the matrix all columns having a 1 in the first row. Continue
the process row by row until no further opportunity exists for shifting
columns.

Machine #
Part # 5 4 2 3 1 # of 1s
3 1 1 1 3
6 1 1 2
4 1 1 2
1 1 1 2
5 1 1
2 1 1
`# of 1s 2 2 2 2 3
Family Formation
Step 4. Sort the rows. Column by column ,beginning with the left most
column, shift rows upward when opportunities exist to form blocks of
1s.

Machine #
Part # 5 4 2 3 1 # of 1s
3 1 1 1 3
6 1 1 2
5 1 1
4 1 1 2
1 1 1 2
2 1 1
# of 1s 2 2 2 2 3
Family Formation

Step 5. Form cells. Look for opportunities to form cells such that all
processing for each part occurs in a single cells.

Machine #
Part # 5 4 2 3 1
3 1 1 1
6 1 1
5 1
4 1 1
1 1 1
2 1
Example 1:
Machine#
1 2 3 4
* *
Part# 1
2 *
3 *
4 * *
Example 2:
Machine#
1 2 3 4 5
Part# 1 * *
2 *
3 * * *
4 * *
5 *
6 * *
Example 3:
Machine #
Part # 1 2 3 4 5 # of 1s
1 1 1 2
2 1 1
3 1 1 1 3
4 1 1 2
5 1 1 2
6 1 1 2
# of 1s 3 2 3 2 2
Ordered machine-part matrix
Machine #
Part # 5 4 2 3 1 # of 1s
3 1 1 1 3
6 1 1 2
5 1 1 2
4 1 1 2
1 1 1 2
2 1 1
# of 1s 2 2 2 3 3
Machine #
Part # 5 4 2 3 1
3 1 1 1
6 1 1
5 1 1
4 1 1
1 1 1
2 1
(a)
Machine #
Part # 5 4 2 3 1
3 1 1 1
6 1 1
5 1 1
4 1 1
1 1 1
2 1
(b)
Machine #
Part # 5 4 2 3 1
3 1 1 1
6 1 1
5 1 1
4 1 1
1 1 1
2 1
(c)
Cell formation with duplicate machine 2

Machine #
Part # 5 4 2a 2b 3 1
3 1 1 1
6 1 1
5 1 1
4 1 1
1 1 1
2 1
Cell formation with duplicate machine 3

Machine #
Part # 5 4 2 3a 3b 1
3 1 1 1
6 1 1
5 1 1
4 1 1
1 1 1
2 1

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