Cellular Manufacturing

Lean Manufacturing , Cell Design

Systematic approach of identifying & eliminating waste. Improved Quality, Higher throughput,

Better efficiency. To do more & more with less & less – Less

men, less equipment, less time, less space, less material.

Lean Manufacturing , Cell Design

Traditional System of Manufacturing –

- Production based on demand forecast.

- Storage of Material & Components till required

for processing.

- Actual production with stress on large batches.

- Storage of components required for assembly.

- Assembly, final inspection & packaging.

- Storage of finished goods in company Godowns;

Zonal depots ; retail outlets.

Lean Manufacturing , Cell Design

Weakness of traditional system -

- Risk related to forecasts. - Long overall business cycle.

- Buffers in various stages leading to slackness in

the system.

- Encourages departmental focus.

Lean Manufacturing , Cell Design

Wastes associated with traditional system –

- Waste due to waiting time of men, machine, material

- Waste due to un-necessary movement of material.

- Waste due to In-process inventory.

- Waste due to producing defective goods.

Lean Manufacturing , Cell Design

Lean manufacturing system –

- Produce against order – As per Takt time- JIT receipt of material

- Pull system

Lean Manufacturing , Cell Design

Key Principals –

- Minimize Material handling, Gravity feed, Handle

products once only.

- Minimize distance – Create cells, Avoid walking,

carrying.

- Minimize strain – Ergonomic design, Hydro

pneumatic clamping.

Lean Manufacturing , Cell Design

Key Principals –

- Minimize clutter – parts, tools, gauges, products at

designated places, 5S.

- Minimize storage.

- Maximize utilization of – People, space, equipment.

- Maximize flexibility : Personal – Multi skilling

Equipment – SMED.

Lean Manufacturing , Cell Design

Key Principals –

- Maximize visibility – Quality spot problem.

- Maximize communication –

Sunrise meetings,

Daily plan Vs achieved.

The Component (Ball Pin)

Cell Lay out

BTBMSPM

Drilling Thread Rolling GatewayOUT

CNC TurningGateway

IN

Ball Pin Cell

M/c No

M/c Operation

Cycle time in Seconds

Unload load

Inspect Walk M/c auto

1 CNC Late

Profile turning

4 4 4 to m/c 2 25

2 BTBM (SPM)

Ball Turning

6 - 4 to m/c 3 14

3 Bench drill

Centering 4 - 4 to m/c 4 6

4 Thread Rolling

Threading 3 - 4 to m/c 1 7

Socket CellP

illar

dri

ll

CNC Lathe Bench drill CNC Lathe Thread Rolling

Pil

lar

Dri

ll

Socket Cell

M/c No

M/c Operation

Cycle time in SecondsUnload Load

Inspect Walk M/c Auto

1 Pillar drill Rough Drill 6 - 4 to m/c 2 20

2 CNC Lathe Socket turning 4 4 4 to m/c 3 35

3 Bench drill Centering 3 - 6 to m/c 1 6

4 CNC Lathe Stem turning 6 4 4 tom/c 5 32

5 Thread Rolling

Threading 3 - 4 to m/c 6 8

6 Pillar drill Back opening 4 - 6 to m/c 4 10