Cellular Layout Theory and Example

Cellular Manufacturing is an application of group technology in which dissimilar machines or

processes have been aggregated into cells.
In general, an individual part of the family will have some of the features that characterize the
family but not all of them. The composite part possesses all the features.

Parts which can be grouped into a cell have different design features or asperity.
Single machine cell consists of one machine plus supporting fixtures and tooling.
This type of cell can be applied to work parts whose attributes allow them to be made on one
basis type of process, such as turning or milling.

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A group machine cell with manual handling is an arrangement of more than one machine used
collectively to produce one or more part families.
There is no provision for mechanized parts movement between the machines in the cell. Instead,
the human operators who run the cell perform the material handling function. The cell is often
organized into a U-shaped layout.

Processing manual (Proc Man)

Group machine cell with semi-integrated handling uses a mechanized handling system, such as a
conveyor, to move parts between machines in the cell.

(a) In-Line layout

(b) Loop Layout

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 (c) Rectangular layout
Improvement using cellular layout:

C or U-shaped cellular Layout

Different Cells may be grouped to form a cellular layout:

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Comparison of key elements in functional and cellular layout:

Various moves in cellular layout with layout:

1) Repeat Operation, in which a consecutive operation is carried out on the same machine so
that the part does not actually move. [Multiple stations]
2) In-sequence move, in which the part moves from the current machine to an immediate
neighbour in the forward direction. [In-line layout/ U-shaped layout]
3) By-passing move, in which the part moves forward from the current machine to another
machine that is two or more machines ahead. [ U-shaped layout]
4) Backtracking move, in which the part moves from the current machine in the backward
direction to another machine. [ / ‫ﻟ‬ ‫ﻟ‬ ‫ﻟ‬ 8‫ﺣﯿﺚ ﯾﺘﻢ ﺗﻨﻔﯿﺬ ﻋﻤﻠﯿﺔ‬
‫ﻣﺘﺘﺎﻟﯿﺔ ﻋﻠﻰ ﻧﻔﺲ اﻟﺠﮭﺎز‬
5) ‫ وﻓﯿﮫ ﯾﻨﺘﻘﻞ اﻟﺠﺰء ﻣﻦ اﻵﻟﺔ اﻟﺤﺎﻟﯿﺔ إﻟﻰ اﻵﻟﺔ‬،‫) اﻟﻨﻘﻞ اﻟﺘﺴﻠﺴﻠﻲ‬2 [‫ ]ﻣﺤﻄﺎت ﻣﺘﻌﺪدة‬.‫أن اﻟﺠﺰء ﻻ ﯾﺘﺤﺮك ﻓﻌﻠﯿﺎ‬
‫اﻟﺤﺎﻟﯿﺔ‬
6) ‫ﺗﺨﻄﯿﻂ ﻋﻠﻰ ﺷﻜﻞ ﺣﺮف‬/‫ ]ﺗﺨﻄﯿﻂ ﻣﻀﻤﻦ‬.‫ اﻟﺠﺎر ﻓﻲ اﻻﺗﺠﺎه اﻷﻣﺎﻣﻲ‬U] 3) ‫ وﻓﯿﮫ ﯾﺘﺤﺮك اﻟﺠﺰء‬،‫اﻟﻨﻘﻞ اﻻﻟﺘﻔﺎﻓﻲ‬
‫ﻟﻸﻣﺎم ﻣﻦ اﻵﻟﺔ اﻟﺤﺎﻟﯿﺔ إﻟﻰ أﺧﺮى‬
7) ‫ ]ﺗﺨﻄﯿﻂ ﻋﻠﻰ ﺷﻜﻞ ﺣﺮف‬.‫ آﻟﺔ أﻣﺎﻣﮭﺎ ﺟﮭﺎزان أو أﻛﺜﺮ‬U] 4) ‫ وﻓﯿﮫ ﯾﺘﺤﺮك اﻟﺠﺰء ﻣﻦ اﻵﻟﺔ اﻟﺤﺎﻟﯿﺔ‬،‫اﻟﻨﻘﻞ اﻟﻌﻜﺴﻲ‬
8) ‫إﻟﻰ اﻟﺨﻠﻒ‬ 4
‫ ]ﺗﺨﻄﯿﻂ ﺣﻠﻘﺔ أو ﻣﺴﺘﻄﯿﻠﺔ‬.‫]اﻻﺗﺠﺎه إﻟﻰ ﺟﮭﺎز آﺧﺮ‬
Rank order clustering:
The Rank Order Clustering (ROC) technique is specifically applicable to production flow analysis.
It is an efficient and easy-to-use algorithm for grouping machines into cells.
Example: Apply the Rank Order Clustering (ROC) technique to the part-machine incidence
matrix shown below. Also, prepare the layout of the obtained solution.
Machines / Parts P1 P2 P3 P4 P5 P6 P7 P8 P9
M1 1 1 1
M2 1 1
M3 1 1 1
M4 1 1
M5 1 1
M6 1 1
M7 1 1 1
Solution (All steps are compulsory for the solution):
Iteration 1: Finding values (Row wise).
Binary values 28 27 26 25 24 23 22 21 20 Value Rank
Machines / Parts P1 P2 P3 P4 P5 P6 P7 P8 P9
M1 1 1 1 290 1
M2 1 1 17 7
M3 1 1 1 81 5
M4 1 1 136 4
M5 1 1 258 2
M6 1 1 65 6
M7 1 1 1 140 3
Iteration 2: Rearranging in decreasing order and finding values (Column-wise).
Machines / Parts P1 P2 P3 P4 P5 P6 P7 P8 P9 Binary Value
M1 1 1 1 26
M5 1 1 25
M7 1 1 1 24
M4 1 1 23
M3 1 1 1 22
M6 1 1 21
M2 1 1 20
Value 96 24 6 64 5 24 16 96 7
Rank 1 4 8 3 9 5 6 2 7
Iteration 3:
Machines / Parts P1 P8 P4 P2 P6 P7 P9 P3 P5
M1 1 1 1
M5 1 1
M7 1 1 1
M4 1 1
M3 1 1 1
M6 1 1
M2 1 1

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Repeat the iteration 1 and 2 if not getting Machine Clustering or Grouping for the Group Layout:
Answer:
Group-I [M1, M5: P1, P8, P4]
Group-II [M4, M7: P2, P6, P7]
Group-III [M2, M3, M6: P3, P5, P9]

Linear cellular manufacturing layout:

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 I-Type, L-Type, U Type and S-Type

1) Linear or I-shaped Cellular Layout

A linear or I-shaped cellular manufacturing layout is a factory floor plan where machines
are arranged in a linear sequence to produce a product. This type of layout is designed to
reduce the movement and labor required to make a product, resulting in shorter production
times, lower costs, and improved quality. Additionally, this type of layout helps provide
‫ﻶﺢﻄﺋ ﻶﻄ ﺜ‬ ‫ﺢﺜﺜﻶﻄ‬ ‫ﻄ‬ ‫ﻶ ﻄ‬ ‫ﺢ ﻶ ﻄﺋ ﻶﻄ‬ ‫ﻶ‬ ‫ﺨﻄﻲ أو ﻋﻠﻰ ﺷﻜﻞ ﺣﺮفھ‬
‫ ﺗﻢ ﺗﺼﻤﯿﻢ ھﺬا اﻟﻨﻮع ﻣﻦ اﻟﺘﺨﻄﯿﻂ‬.‫ﻣﺨﻄﻂ ﻷرﺿﯿﺔ اﻟﻤﺼﻨﻊ ﺣﯿﺚ ﯾﺘﻢ ﺗﺮﺗﯿﺐ اﻵﻻت ﻓﻲ ﺗﺴﻠﺴﻞ ﺧﻄﻲ ﻹﻧﺘﺎج ﻣﻨﺘﺞ‬
‫ ﻣﻤﺎ ﯾﺆدي إﻟﻰ إﻧﺘﺎج أﻗﺼﺮ‬،‫ﻟﺘﻘﻠﯿﻞ اﻟﺤﺮﻛﺔ واﻟﻌﻤﺎﻟﺔ اﻟﻤﻄﻠﻮﺑﺔ ﻟﺘﺼﻨﯿﻊ اﻟﻤﻨﺘﺞ‬
‫ ﯾﺴﺎﻋﺪ ھﺬا اﻟﻨﻮع ﻣﻦ اﻟﺘﺨﻄﯿﻂ ﻋﻠﻰ ﺗﻮﻓﯿﺮ اﻟﻮﺻﻮل اﻟﺴﺮﯾﻊ‬،‫ ﺑﺎﻹﺿﺎﻓﺔ إﻟﻰ ذﻟﻚ‬.‫ وﺗﺤﺴﯿﻦ اﻟﺠﻮدة‬،‫ وﺗﻜﺎﻟﯿﻒ أﻗﻞ‬،‫ﻣﺮات‬
‫واﻟﺴﮭﻞ إﻟﻰ اﻷﺟﺰاء واﻟﻤﻮاد‬.

2) U-shaped Cellular Manufacturing Layout

A U-shaped cellular manufacturing layout is a production line layout where machines are
arranged in a U-shape, allowing for easy access to each station by the operator. This type
of configuration has the advantage of allowing for quick and efficient workflows, and the
proximity of machines to each other often allows for reduced cycle times. It also makes it
easier to track and monitor the production process and identify any potential problems
quickly.‫ ﺧﻄﯿﻂ اﻟﺘﺼﻨﯿﻊ اﻟﺨﻠﻮي ﻋﻠﻰ ﺷﻜﻞ ﺣﺮف‬U ‫ھﻮ ﺗﺨﻄﯿﻂ ﻟﺨﻂ اﻹﻧﺘﺎج ﺣﯿﺚ ﯾﺘﻢ ﺗﺮﺗﯿﺐ اﻵﻻت ﻋﻠﻰ ﺷﻜﻞ ﺣﺮ‬

3) O-shaped Cellular Manufacturing Layout

An O-shaped cellular manufacturing layout is an arrangement of machines and
workstations in which each workstation is located in a separate, distinct area (cell) within
the production facility. The machines and workstations are arranged in an 'O' shape, with
the devices located at the outside of the 'O' and the workstations located in the middle of
the 'O'. This type of layout facilitates the flow of materials, reduces material handling costs,
and allows for quick product changeover. The layout also encourages machine operators
to work together as a team and helps reduce production costs.‫ﺗﺨﻄﯿﻂ اﻟﺘﺼﻨﯿﻊ اﻟﺨﻠﻮي ﻋﻠﻰ ﺷﻜﻞ‬
O ‫ھﻮ ﺗﺮﺗﯿﺐ ﻟﻶﻻت وﻣﺤﻄﺎت اﻟﻌﻤﻞ ﺣﯿﺚ ﺗﻘﻊ ﻛﻞ ﻣﺤﻄﺔ ﻋﻤﻞ ﻓﻲ ﻣﻨﻄﻘﺔ )ﺧﻠﯿﺔ( ﻣﻨﻔﺼﻠﺔ وﻣﺘﻤﯿﺰة داﺧﻞ ﻣﻨﺸﺄة‬
‫ ﯾﺘﻢ ﺗﺮﺗﯿﺐ اﻵﻻت وﻣﺤﻄﺎت اﻟﻌﻤﻞ ﻋﻠﻰ ﺷﻜﻞ‬.‫" اﻹﻧﺘﺎج‬O"، ‫" ﺣﯿﺚ ﺗﻮﺟﺪ اﻷﺟﮭﺰة ﻓﻲ اﻟﺠﺰء اﻟﺨﺎرﺟﻲ ﻣﻦ‬O" ‫وﺗﻘﻊ‬
‫" ﻣﺤﻄﺎت اﻟﻌﻤﻞ ﻓﻲ ﻣﻨﺘﺼﻒ‬O". ‫ وﯾﺴﻢ‬،‫ وﯾﻘﻠﻞ ﻣﻦ اﻟﻤﻮاد ﺗﻜﺎﻟﯿﻒ اﻟﻤﻨﺎوﻟﺔ‬،‫ھﺬا اﻟﻨﻮع ﻣﻦ اﻟﺘﺨﻄﯿﻂ ﯾﺴﮭﻞ ﺗﺪﻓﻖ اﻟﻤﻮاد‬7

4) T-shaped Cellular Manufacturing Layout

A T-shaped cellular manufacturing layout is an arrangement of production equipment and
workers in a factory in which machines are arranged in the shape of a “T,” with the vertical
 line representing the main production line and the horizontal line representing the
secondary production line.
This layout facilitates the efficient movement of materials and workers between the
production lines, allowing for a more efficient production process.

5) S-shaped Cellular Manufacturing Layout

An S-shaped Cellular Manufacturing Layout is a manufacturing production system in
which machines are arranged in a U- or S-shaped configuration. This arrangement allows
for more efficient production. This is because the machines are set in a continuous loop,
and the products can move from one machine to the next without having to be transported
between multiple workstations. This arrangement allows for the elimination of wasted
motion, which in turn leads to increases in productivity and cost savings.‫ﺗﺨﻄﯿﻂ اﻟﺘﺼﻨﯿﻊ‬
‫ اﻟﺨﻠﻮي ﻋﻠﻰ ﺷﻜﻞ ﺣﺮف‬T ‫" ھﻮ ﺗﺮﺗﯿﺐ ﻟﻤﻌﺪات اﻹﻧﺘﺎج واﻟﻌﻤﺎل ﻓﻲ ﻣﺼﻨﻊ ﺣﯿﺚ ﯾﺘﻢ ﺗﺮﺗﯿﺐ اﻵﻻت ﻋﻠﻰ ﺷﻜﻞ ﺣﺮف‬
T"، ‫ ﯾﺴﮭﻞ ھﺬا اﻟﺘﺨﻄﯿﻂ‬.‫ﺣﯿﺚ ﯾﻤﺜﻞ اﻟﺨﻂ اﻟﻌﻤﻮدي ﺧﻂ اﻹﻧﺘﺎج اﻟﺮﺋﯿﺴﻲ واﻟﺨﻂ اﻷﻓﻘﻲ ﯾﻤﺜﻞ ﺧﻂ اﻹﻧﺘﺎج اﻟﺜﺎﻧﻮي‬
‫ ﻣﻤﺎ ﯾﺴﻤﺢ ﺑﻌﻤﻠﯿﺔ إﻧﺘﺎج أﻛﺜﺮ ﻛﻔﺎءة‬،‫اﻟﺤﺮﻛﺔ اﻟﻔﻌﺎﻟﺔ ﻟﻠﻤﻮاد واﻟﻌﻤﺎل ﺑﯿﻦ ﺧﻄﻮط اﻹﻧﺘﺎج‬.
the most common work cell layouts for optimized design are U, T, S, and Z. All four of
these work cell design layouts allow a streamlined workflow process from one cell to the
next. S and Z layouts are often used if and when obstructions like CNC machines or pillars
are in the way; they allow you to work around these types of obstructions.