Dr. Nahed Sobhi Dr. Nahed Sobhi

Y

Dr. Nahed Sobhi
Sherif Masoud
Ahmed Badr
Ahmed Abdallah
Y

K
v Background
v Cellular machine layout based on
Segmented Flow Topology
v Algorithms for production flow analysis
v Family--based scheduling of shops with
Family
functional layouts
v Quantitative and qualitative indices for the
plant layout evaluation problem
!
v °roup Technology (°T) is a manufacturing
concept that uses the similarities of produced
parts in order to increase production efficiency.
v The concept of °T was originally proposed by
Mitrofanov in the book named !

that was
published in 1966.
v Cellular Manufacturing (CM) is an application of
°T concepts to factory and shop floor layout
design
j "
v A manufacturing cell can be defined as ³an
independent group of functionally dissimilar
machines, located together on the floor,
dedicated to the manufacturing of a family of
similar parts.´(1)
v A part family can be defined as ³a collection of
parts which are similar either because of
geometric shape and size or because similar
processing steps are required to manufacture
them.´(1)

Machinery and machine tools
Agricultural and construction equipment
Hospital and medical equipment
Defense products
Automobiles and engines
Piece parts and components
Electronic products
Chemical equipment
Packaging industries

Cell has a range of values for the number of people (1-

(1-6)
and workstations (1-
(1-10) and its own entrance and exit
Machines are laid out in a U-

U-layout to simplify and
minimize material movement.
Cell does its own inspection and work scheduling.
Cell produces a family of similar parts that requires

similar machines, or workstations, in the cell.(1)
á

1. Machining center
2. Single operator, multiple machines
3. Single
Single-- robot automated cell
4. Multiple machines, multiple operators
5. Multiple robots, automated cell
6. Assembly cell
m

v The tangible advantages of manufacturing cells
are due to the proximity of all machines required
to make a family of parts.(1)
v This reduces the total distance required to be

traveled by the batches of parts in the family.
v Manufacturing cells are the first step in the

implementation of Computer-
Computer-Aided Design,
Computer--Aided Manufacturing, Flexible
Computer
Manufacturing Systems
i

v =eed for high investment in machine installation
and re-
re-layout
v Lack of flexibility in handling demand changes,

product mix changes, infrequent ordering of
parts, variable lo sizes
v Imbalance of utilization of machines and labor
v Lack of a comprehensive cell formation method
v Data collection and analysis is time-

time-consuming
j "
v áyeballing
v Production Flow Analysis (PFA)
v Parts
Classification and Coding
(C&C)
#
v Úisual inspection method is the simplest and
least expensive method.
v Classification of parts into families by looking

either at the parts themselves or their drawings
and arranging them into groups based on general
criteria
v Accuracy of grouping obtained by this method is

generally considered to be the least among the
three methods.(1)
Ä
m
v !

v !

v !

v !

Ä

Ê Parts Classification and Coding is a highly time-
time-
consuming and complicated activity.
Ê Attributes of a part such as dimensions, shape

features, auxiliary holes, or gear teeth are
captured in a code number
Ê The cell for each family is identified by matching

the attributes of parts in each family to machine
capabilities

Ê This paper introduces a facility layout design
procedure for converting an existing
manufacturing system with a predefined aisle
structure to a cellular manufacturing system
based on the Segmented Flow Topology (SFT) .
Ê the best machine grouping along with the

locations of pick-
pick-up and delivery stations and
machine layout for each cell based on an existing
facility. The objective is to minimize the total
material handling cost .
m

Ê This paper describes a set of algorithms
which seek to automate the different
phases of analysis in this classical design
method for Cellular
Ê In particular, this paper describes an

enhanced machine-
machine-part matrix clustering
(MPMC) algorithm to automate the °roup
Analysis phase of PFA.

Yhis study was motivated by the

case of an existing real-
real-world semi-
semi-
conductor testing facility that has
family setups, parallel machines
and dynamic job arrival
Ñ

°eneric approaches for developing

quantitative and qualitative indices are
provided and new indices for the flow
criterion group and environment
criterion are presented in this paper.
Y !$

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Cell has a range of values for the number of people (1-

Machines are laid out in a U-

Cell does its own inspection and work scheduling.

Cell produces a family of similar parts that requires

2. Single operator, multiple machines

4. Multiple machines, multiple operators

5. Multiple robots, automated cell

v This reduces the total distance required to be

v Manufacturing cells are the first step in the

v Lack of flexibility in handling demand changes,

v Imbalance of utilization of machines and labor

v Lack of a comprehensive cell formation method

v Data collection and analysis is time-

v Production Flow Analysis (PFA)

v Classification of parts into families by looking

v Accuracy of grouping obtained by this method is

Ê Attributes of a part such as dimensions, shape

Ê The cell for each family is identified by matching

Ê the best machine grouping along with the

Ê In particular, this paper describes an

Yhis study was motivated by the

°eneric approaches for developing

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