GROUP TECHNOLOGY

CHAPTER 3
 INTRODUCTION TO GT

• Group technology (GT) is a manufacturing philosophy

that seeks to improve productivity by grouping parts
and products with similar characteristics into families
and forming production cells with a group of dissimilar
machines and processes.
• The group of similar parts is known as part family and
the group of machineries used to process an individual
part family is known as machine cell. It is not necessary
for each part of a part family to be processed by every
machine of corresponding machine cell.
• Group technology begun by grouping parts into
families, based on their attributes (Geometry,
manufacturing process).
 WHY GROUP TECHNOLOGY?
• AVERAGE LOT SIZE DECREASING
• PART VARIETY INCREASING
• INCREASED VARIETY OF MATERIALS WITH
DIVERSE PROPERTIES
• REQUIREMENTS FOR CLOSER TOLERANCES

A FAMILY OF PARTS
 PRODUCTION FAMILY

THIRTEEN PARTS WITH

SIMILAR MANUFACTURING
PROCESS REQUIREMENTS
BUT DIFFERENT DESIGN
ATTRIBUTES

LACK OF COMMON DATABASE FOR MFG., DESIGN...

• DON’T “REDESIGN THE WHEEL”
• AUTOMATED PROCESS PLANNING
• DATABASE TO DRIVE THE AUTOMATED FACTORY
Parts grouped by geometric shape
Parts grouped by manufacturing process
Features of group technology
• Objective: To make batch production more efficient and
productive. To integrate design and manufacturing in a
firm.
• Obstacle: Identifying the part families. Rearranging
production machines into machine cells
• Benefits: It promotes standardization. It reduces
material handling, setup times and work-in-process.
Worker satisfaction and quality work improve
 Group technology
• Reduced production lead time
• Reduced work-in-process
• Reduced labor
• Reduced tooling
• Reduced rework and scrap materials
• Reduced setup time
• Reduced order time delivery
• Improved human relations
• Reduced paper work
• Geometric classification of families is normally based
on size and shape, while production process
classification is based on the type, sequence, and
number of operations. The type of operation is
determined by such things as the method of
processing, the method of holding the part, the
tooling.

There are three methods that can be used to form part

families:
– Manual visual inspection
– Production flow analysis
– Classification and coding
Manual visual inspection involves arranging a set of
parts into groups by visually inspecting the physical
characteristics of the parts.
 Manual visual inspection

Part Family 1

Part Family 2
 Production Flow Analysis
• Production flow analysis (PFA) is a method for
identifying part families and associated machine
groupings that uses the information contained on
production route sheets rather than on part
drawings.
• Workparts with identical or similar routings are
classified into part families. Then, the families can be
used to form logical machine cells in a group
technology layout.
- Parts that go through common operations are
grouped into part families.
- The machines used to perform these common
operations may be grouped as a cell, consequently
this technique can be used in facility layout (factory
layout)
• PFA Chart: The processes used for each pack are then
displayed in a PFA chart.
PFA chart has been referred as part-machine incidence
matrix.

xij = 1  Part i requires processing on machine j

xij = 0  Part i is not processed on machine j
Cluster analysis: From the pattern of data in the PFA chart,
related groupings are identified a rearranged into a new
pattern that brings together packs with similar machine
sequences.
- Different machine groupings are indicated with blocks.
- The blocks might be considered as possible machine cells.

Weakness: The data used in the technique are derived form

existing production route sheets. The routings may contain
operations that are non-optimal, illogical or unnecessary.
Production flow
analysis
Quantitative analysis in cellular manufacturing
1. Rank Order Clustering Algorithm
Rank Order Clustering Algorithm is a simple algorithm
used to form machine-part groups.
Step 1: Assign binary weight and calculate a decimal weight
for each row.
Step 2: Rank the rows in order of decreasing decimal
weight values.
Step 3: Repeat steps 1 and 2 for each column.
Step 4: Continue preceding steps until there is no change in
the position of each element in the row and the
column.
 Example #1
Consider a problem of 5 machines and 6 parts. Try to group
them by using Rank Order Clustering Algorithm.

Part ‘Number’
1 2 3 4 5 6
A 1 1
Mac B 1 1
hine
ID C 1 1
D 1 1 1
E 1 1 1
 Step 1:

Decimal
Part Numbers equivalent
Rank

1 2 3 4 5 6
B.
25 24 23 22 21 20
Wt:

Ma A 1 1 23+21 = 10 5
chi B 1 1 24+23 = 24 4
ne
ID C 1 1 25+22=36 2
24+23+21 =
D 1 1 1 3
26

E 1 1 1 25+22+20=37 1

Step 2: Must Reorder!

 Step 2:

Part Number

1 2 3 4 5 6

E 1 1 1
C 1 1
Machine
D 1 1 1
ID
B 1 1
A 1 1
 Step 3

Part Number

B. WT. 1 2 3 4 5 6

E 24 1 1 1
C 23 1 1
Machine
D 22 1 1 1
ID
B 21 1 1
A 20 1 1
Decimal 24+23 22+21= 22+21+ 24+23= 22+20= 4
2 =16
equivalent = 24 6 20=7 24 5
Rank 1 5 4 2 6 3

Step 4: Must Reorder

 Back at Step 1

Part Number D. Eqv Rank

1 4 6 3 2 5
B Wt: 25 24 23 22 21 20

E 1 1 1 25+24+ 23=56 1

C 1 1 25+24= 48 2

D 1 1 1 22+21+ 20 = 7 3

B 1 1 22+21=6 4

A 1 1 22+20=5 5

Order stays the same: STOP!

 Example #2

Part Number
Ma 1 2 3 4 5 6 7
chi
ne
ID A 1 1 1
B 1 1
C 1 1 1 1
D 1 1 1
E 1 1 1 1
 Step 1: Assign binary weight and calculate a decimal weight for each row

Part Number
1 2 3 4 5 6 7 Equivalent Rank
decimal value
Ma Binary wt. 26 25 24 23 22 21 20
chi
ne
ID A 1 1 1 41 3
B 1 1 20 5
C 1 1 1 1 105 1
D 1 1 1 82 2
E 1 1 1 1 40 4
 Step 3: Reorder the matrix according to rank

Part Number
Ma 1 2 3 4 5 6 7
chi
ne
ID C 1 1 1 1
D 1 1 1
A 1 1 1
E 1 1 1 1
B 1 1
Step 4: Assign binary weight and calculate a decimal weight for each Column

Part Number
Ma Binary wt. 1 2 3 4 5 6 7
chi
ne
ID
C 16 1 1 1 1
D 8 1 1 1
A 4 1 1 1
E 2 1 1 1 1
B 1 1 1
Equ. Decimal 24 20 11 22 3 10 20
Value
Rank 1 3 5 2 7 6 4
 Step 5: Reorder the matrix according to rank

Part Number
Ma 1 4 2 7 3 6 5
chi
ne
ID C 1 1 1 1
D 1 1 1
A 1 1 1
E 1 1 1 1
B 1 1
Repeat Step 1&2: Assign binary weight and calculate a decimal weight for each row

Part Number
1 4 2 7 3 6 5 Equivalent Rank
decimal value
Ma Binary wt. 26 25 24 23 22 21 20
chi
ne
ID C 1 1 1 1 120 1
D 1 1 1 70 2
A 1 1 1 56 3
E 1 1 1 1 39 4
B 1 1 5 5
Order stays the same:
 Repeat Step 4 & 5

Part Number
Ma Binary wt. 1 4 2 7 3 6 5
chi
ne C 16 1 1 1 1
ID
D 8 1 1 1
A 4 1 1 1
E 2 1 1 1 1
B 1 1 1
Equ. Decimal 24 22 20 20 11 10 3
Value
Rank 1 2 3 4 5 6 7
Order stays the same: STOP!
 Voids Exceptional
parts Part family 1: Part Nos. 1, 4, 2 & 7

Part Number
Machine Cell 1: C, D & A
M 1 4 2 7 3 6 5
ac Part family 2: Part Nos. 3, 5, and 5
C 1 1 1 1 Machine Cell 2: E & B
hi
n D 1 1 1
e No. of exceptional Parts: 3
ID A 1 1 1
E 1 1 1 1 No. of Voids: 5

B 1 1 No. of bottleneck machines:

2(Machines D & E)

Solutions for overcoming this problem?

• Duplicate machines
• Alternate process plans
• Subcontract these operations
 Duplicate machines

Part Number Part Number

M 1 4 2 7 3 6 5 M 1 4 2 7 3 6 5
a C 1 1 1 1 a
C 1 1 1 1
c c
h D 1 1 1 hi D 1
i A 1 1 1 n A 1 1 1
n e
e E 1 1 1 1 ID E 1
I B 1 1 E 1 1 1
D
No. of exceptional Parts: 3 B 1 1

No. of Voids: 5 D 1 1

No. of bottleneck machines: No. of exceptional Parts: 0

2(Machines D & E) No. of Voids: 9
No. of bottleneck machines: 0
No. of duplicate machine: 2(Machines
D&E
 Alternate process plans

Part Number Part Number

M 1 4 2 7 3 6 5 M 1 4 2 7 3 6 5
a a
C 1 1 1 1 C 1 1 1 1
c c
h D 1 1 1 hi A 1 1 1
i A 1 1 1 n E 1 1 1 1
n e
e E 1 1 1 1 ID B 1 1
I B 1 1 D 1 1 1
D
No. of exceptional Parts: 3 No. of exceptional Parts: 2
No. of Voids: 5 No. of Voids: 3
No. of bottleneck machines: No. of bottleneck machines:
2(Machines D & E) 2(Machines D & E
 2. Arranging Machines in a GT Cell

• After part-machine grouping have been identified by rank order

clustering, the next problem is to organize the machines into the
most logical arrangement.
• Hollier Method. This method uses the sums of flow “From” and “To”
each machine in the cell. The method can be outlined as follows
1. Develop the From-To chart from part routing data. The data
contained in the chart indicates numbers of part moves between the
machines in the cell.
2. Determine the “From” and “To” sums for each machine. This is
accomplished by summing all of the “From” trips and “To” trips for
each machine.
 The “From” sum for a machine is determined by adding the
entries in the corresponding row.
 The “To” sum is found by adding the entries in the corresponding
column.
3. Assign machines to the cell based on minimum “From” or “To” sums. The
machine having the smallest sum is selected.
 If the minimum value is a “To” sum, then the machine is placed at
the beginning of the sequence.
 If the minimum value is a “From” sum, then the machine is placed at
the end of the sequence.
Tie breaker
 If a tie occurs between minimum “To” sums or minimum “From”
sums, then the machine with the minimum “From/To” ratio is
selected.
 If both “To” and “From” sums are equal for a selected machine, it is
passed over and the machine with the next lowest sum is selected.
 If a minimum “To” sum is equal to a minimum “From” sum, then
both machines are selected and placed at the beginning and end of
the sequence, respectively
4. Reformat the From-To chart. After each machine has been selected,
restructure the From-To chart by eliminating the row and column
corresponding to the selected machine and recalculate the “From” and
“To” sums.
 Example of Arranging Machines in a GT Cell
Suppose that four machines, 1, 2, 3, and 4 have been identified as
belonging in a GT machine cell. An analysis of 50 parts processed
on these machines has been summarized in the From-To chart
presented below. Additional information is that 50 parts enter the
machine grouping at machine 3, 20 parts leave after processing at
machine 1, and 30 parts leave after machine 4. Determine a logical
machine arrangement using Hollier method.
First iteration

Second iteration with machine 3 removed

Third iteration with machine 2 removed

The resulting machine sequence 3  2  1  4

The flow diagram for machine cell in the Example is shown below. Flow of
parts into and out of the cells has also been included
 Parts classification and coding
• Definition: Each part family is exclusively identified
by an alpha-numerical code, which represents
their design attributes, manufacturing attributes or
both.
• Feature:
- Advantage: Design retrieval; Automated process
planning; Machine cell design
- Methods to obtain the code from a particular
part: Looking in tables to match the subject part
against the features described. Using a
computerized classification and coding system to
reply questions about the part’s features
 Classification and Coding
• Coding refers to the process of assigning symbols to the parts
• The symbols represent design attributes of parts or
manufacturing features of part families

• Although well over 100 classification and coding systems have

been developed for group technology applications, all of them can
be grouped into three basic types:
– Monocode or hierarchical code
– Polycode or attribute
– Hybrid or mixed code
 MONOCODE (HIERARCHICAL CODE)

• This coding system was originally developed for biological classification in

18th century.

• In this type of code, the meaning of each character is dependent on the

meaning of the previous character; that is, each character amplifies the
information of the previous character. Such a coding system can be
depicted using a tree structure

Monocode of Fig. 1:
Fig. 1 Spur gear
A-1-1-B-2
hierarchical code for
the spur gear
 POLYCODE (ATTRIBUTE CODE)

• The code symbols are independent of each other

• Each digit in specific location of the code describes a
unique property of the workpiece
– it is easy to learn and useful in manufacturing situations
where the manufacturing process have to be described
– the length of a polycode may become excessive because of
its unlimited combinational features
 POLYCODE (ATTRIBUTE CODE):

Polycode for the spur gear (Fig. 1): 22213

 MIXED CODE (HYBRID CODE):
• In reality, most coding systems use a hybrid (mixed) code so that the
advantages of each type of system can be utilized. The first digit for
example, might be used to denote the type of part, such as gear. The next
five position might be reserved for a short attribute code that would
describe the attribute of the gear. The next digit (7th digit) might be used
to designate another subgroup, such as material, followed by another
attribute code that would describe the attributes.