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Cell Layout

Chapter · January 2015

DOI: 10.1002/9781118785317.weom100050

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Cell Layout The usual basic options for laying out facilities
are FIXED POSITION LAYOUT, PROCESS
LAYOUT, and PRODUCT LAYOUT. A cell layout
is actually a hybrid facility arrangement based
on combining some of the principles of fixed
position and product layouts. A cell layout
involves grouping together a number of dissimilar
machines or processes according to the
design of the product being made or the operations
required for its production. In this respect,
a cell layout is similar to a product layout. The
main difference, however, is that in a cell layout,
the operation sequence and flow direction can
be varied. Another important difference is that
the workers in a cell are usually multi skilled and
can operate more than one machine or process,
whereas in a product layout, they tend to be
dedicated to just one task on one workstation. In
this respect, therefore, a cell layout draws on one
of the features of the fixed position approach.
As with product layouts, a cell layout can
be used in high product-volume situations, but
its use is probably better established in intermittent
batch operations. In this case, the cell
is used to produce PRODUCT FAMILIES rather
than a single product and is based on the principles
of ‘‘group technology.’’ Here, the cell
(or group of processes) and associated family
(or group) of products/parts can be identified
using a number of techniques. Among these are
coding and classification, where products and
parts are identified by a numerical or alphanumeric
coding system, then classified into families
and allocated to cells according to their design
and processing requirements. Coding systems
can be of two types: ‘‘universal’’ systems, which
can be applied to all production situations,
or ‘‘bespoke’’ systems, which are specifically
tailored to the needs of a particular organization.
An alternative approach to cell design is to use
PRODUCTION FLOW ANALYSIS, where operation
route sequence data are analysed to identify
the appropriate combination of product families
and processes. However, this technique has the
disadvantage of being based on existing products
and processes. The ideal approach would be to
design all new products specifically for production
using a cell layout; this should produce a
more efficient overall result.
Originally, cell layouts were associated with
the processing of component parts. However,
they are increasingly becoming regarded as an
appropriate type of layout in connection with
assembly work. In this case, they are often
used for higher product volumes that would
otherwise necessitate using a product layout.
The use of cells overcomes many of the disadvantages
associated with product layouts. For
example, the wider operator skill requirements
provide greater JOB ENRICHMENT, which can
result in less absenteeism, lower labour turnover,
and easier recruitment. Many of the physical
problems associated with product layouts can
also be overcome using assembly cells; a reduction
in workstation interdependency makes the
overall system more reliable and the assembly of
different product variants is easier with cells than
with conventional ‘‘line’’-type product layouts.
Cell layouts for assembly also avoid the need for
LINE BALANCING, and SYSTEM LOSS.
A further aspect to be considered regarding
cell layouts is the use of automation for materials
handling and production operations. In cells for
producing component parts, industrial robots
are frequently used for loading,
unloading, and the transfer of material between
machines. The processes within a cell can also be
automated and computer numerically controlled
(CNC) machine tools are often incorporated in
production cells. Sometimes, the complexity of
these cells is such that they can be defined
as flexible manufacturing. In assembly
cells, an increasingly common form of materials
handling device is the automated guided
vehicle (AGV), which can transport products
both within and between cells under automatic
control. Robots are also starting to be developed with the
necessary dexterity, flexibility, and intelligence
to carry out the type of assembly operations that
at one time could only be done manually.
The concept of the ‘‘cellular’’ arrangement
of facilities has also been used in SERVICE
OPERATIONS. For example, some retail operations might cluster
goods in one area, not
because the goods are similar in their function
but because they conform to a theme recognizable
to customers. A sports goods area in a
department store sells types of goods that might
all be available elsewhere in the store, but are
clustered around the ‘‘sports’’ theme. This cell like
arrangement is sometimes called the ‘‘shop
within a shop’’ concept.
Two additional points that warrant discussion
in relation to manufacturing cell layouts
are concerned with production control and the
payment of workers. As far as production control
is concerned, cells have the benefit of being a
single ‘‘planning point,’’ which means that the
central planning and control function only needs
to be concerned with the cell level rather than
the level of each individual machine and process.
 The cells themselves will have their own individual
controllers, which can be computerized
or manual, and will interface with the central
planning and control function. In this way, the
cell can be largely regarded as an autonomous
production unit or a focused factory. The degree
of autonomy involved and the multi skill requirements
of cells also demand a more appropriate
payment system than that used in other types of
situation. Typically, such a payment system will
include different elements designed to reflect
the characteristics of work carried out in cells

Bibliography
Bollinger, S. (1998) Fundamentals of Plant Layout,
Society of Manufacturing Engineers in association
with Richard Muther and Associates, Dearborn, MI.
Burbidge, J.L. (1978) The Principles of Production Control,
4th edn, Macdonald and Evans, London.
Choobineh, F. (1988) A framework for the design of
cellular manufacturing systems. International Journal
of Production Research, 26 (7), 1161–1172.
Green, T.J. and Sadowski, R.P. (1984) A review of
cellular manufacturing assumptions and advantages
and design techniques. Journal of Operations Management,
4 (2), 85–97.
Heragu, S. (1997) Facilities Design, PWS, Boston.
Kirton, J. and Brooks, E. (1994) Cells in Industry,
McGraw-Hill, London.
Sule, D.R. (1994) Manufacturing Facilities: Location,
Planning and Design, PWS, Boston.

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