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Cellular Manufacturing
CM is an application of group technology in which
all or a portion of a firm’s manufacturing system has been converted into cells. • A manufacturing cell is a cluster of machines or processes located in close proximity and designed to the manufacture of a family of parts. • The parts are similar in their processing requirements, e.g., operations, tolerances, and machine tool capacities. Cellular Manufacturing
• The primary objectives of a CMS are:
– To reduce setup times (by using part family tooling and sequencing); – Flow times (by reducing setup times, move times, and wait time for moves and using smaller batch sizes); – Reduce inventories and market response times Design of CM Systems Cell design • Cell design involves both system structure and system operation. structural issues include: 1. Selection of part families and grouping of parts into families 2. Selection of machine and process populations and grouping these into cells 3. Selection of tools, fixtures, and pallets 4. Selection of material-handling equipment 5. Choice of equipment layout Design of CM Systems Cell design • Cell design involves both system structure and system operation. Issues related to procedures include: 1. Detailed design of jobs 2. Organization of supervisory and support personnel around the cellular structure 3. Formulation of maintenance and inspection policies 4. Design of procedures for production planning, scheduling, control, and acquisition of related software and hardware 5. Modification of cost control and reward systems 6. Outline of procedures for interfacing with the remaining manufacturing system ( in terms of work flow and information, whether computer controlled or not). Part Families • A part family is a collection parts that are similar either because of geometric shape and size or because of similar processing steps. • Parts within a family are different, but have similarities close enough to merit their inclusion as members of the part family. Part Families • Parts shown in the figure are geometrically the same, but quite different in terms of manufacturing; differences in tolerances, production quantities, and material. Part Families • Parts shown in the figure constitute a family in manufacturing, but their geometries are different which makes them appear different from a design viewpoint. Process type plant layout Process type plant layout • Various machines are arranged by function – Lathe dept.; milling machine dept.; drill press dept.; etc. – To machine a part, the workpiece must be transported between departments, perhaps visiting a dept. several times – Significant material handling; large in-process inventory; many machine setups; long manufacturing lead times; and high cost. Group technology layout Group technology layout • The above figure shows a production shop with machines arranged into cells • Each cell is organized to specialize in the production of a particular part family • Advantages are: – Reduced setup times; fewer setups; less in- process inventory, and shorter lead times Analysis of single station systems • A MS must be designed to produce a specific quantity of parts or products at a specific production rate. • In the SSMS, this may mean that more than one single station cell is required to achieve the specifications. • The issue is to determine the number of workstations required to achieve a given production rate or produce a given quantity of units. Analysis of single station systems Number of workstations required • The basic approach is: – To determine the total workload that must be accomplished in a certain period; • workload is defined as the total hours required to complete a given amount of work or to produce a given number of work units for the period. – Then divide the workload by the hours available on one work station in the same period Analysis of single station systems • Workload schedule for a given period (hrs or wks of work etc.) is expressed as follows:
WL = QTc
Q = quantity to be produced during the period
(pc/hr or pc/wk, etc.) Tc = cycle time per piece (hr/pc) Analysis of single station systems For multiple part or product styles produced on the same workstation, the above expression becomes: WL = ∑Q jTcj Q j = quantity of part or product style j produced during the period (pc), Tcj = cycle time of part or product style j (hr/pc). The summation includes all of the parts or product styles Analysis of single station systems Number of workstations n = WL/AT AT = available time on one station in the period (hr/period). Analysis of single station systems Factors which may influence manufacturing systems • Setup time in batch production – During setup, the workstation is not performing • Availability – Reliability factor that reduces the available time (production) • Utilization – Workstation may not be fully utilized due to lack of work for a given machine type, workload imbalance among workstations, etc. • Worker efficiency – For highly manual work, worker performs either above- or below standard performance for the given task • Defect rate – Defective units may be produced at a certain defect rate, and this must be accounted for. Quantitative analysis in cellular manufacturing A number of quantitative techniques have been developed to deal with problem areas in GT and CM: 1. Grouping parts and machines into families 2. Arranging machines in a GT cell Grouping parts and machines Grouping parts and machines by rank order clustering • The problem is to identify and group machines into cells • Identify part families • Three basic methods to identify part families are: 1. Visual inspection, 2. Parts classification and coding, and 3. Production flow analysis Rank order clustering This technique is applicable in production flow analysis. It is an efficient and easy-to-use algorithm for grouping machines into cells. • Rank order works by reducing the part- machine incidence matrix to a set of diagonalized blocks that represent part families and associated machine groups. Rank order clustering Starting with the initial part-machine incidence matrix, the algorithm consists of the following steps: 1. In each row of the matrix, read the series of 1’s and 0’(blanks) from left to right as a binary number. Rank the rows in order of decreasing value. In case of a tie, rank the rows in the order as they appear in the current matrix. 2. Numbering from top to bottom, is the current order of rows the same as the rank order determined in the previous step? If ‘yes’ go to step 7. If ‘no’ then next step. Rank order clustering 3. Reorder the rows in the part-machine incidence matrix by listing them in decreasing rank order, starting from the top. 4. In each column of the matrix, read the series of 1’s and 0’s(blanks) from top to bottom as a binary number. Rank the columns in order of decreasing value. In case of a tie, rank the columns in the order as they appear in the current matrix. 5. Numbering from left to right, is the current order of columns the same as the rank order determined in the previous step? If ‘yes’ go to step 7. If ‘no’ then next step. 6. Reorder the columns in the part-machine incidence matrix by listing them in decreasing rank order, starting with left column. Go to step 1. 7. Stop.