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CELLULAR MANUFACTURING

Presentation By :-

SAGAR S. KURDE Me 747

SAURABH P. GARDI Me 739

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Introduction & Concept

Cellular Manufacturing is a model for workplace design, and has become an integral part of lean manufacturing systems

Cellular Manufacturing takes full advantage of the similarity between parts, through standardization and common processing and groups them into cell.

The goal of cellular manufacturing is the aggressive minimization of waste, to achieve maximum efficiency of resources.

The basic concept of cellular manufacturing is the integration of management practices

with technological advances

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CELLULAR MANUFACTURING Cellular Manufacturing is the

application of the principles of Group Technology in manufacturing. Group Technology was proposed by Flanders in 1925 and adopted in Russia by Mitrofanov in 1933.

Successfully implementing Cellular manufacturing allows companies to achieve cost savings and quality improvements, especially when combined with the other aspects of lean manufacturing.

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CELLULAR MANUFACTURING It is having the flexibility to

produce a high variety of low demand products, while maintaining the high productivity of large scale production.

Cell designers achieve this through both process design and product design. Processes are arranged in a U-shape so that the beginning and end of the material flow within the cell are near each other. This allows quick rebalancing of tasks without redesigning stations.

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CELLULAR MANUFACTURING Traditional

VS.

U-shaped

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Cellular Manufacturing One Piece Flow

One-piece flow is the state that exists when products move through a manufacturing process one unit at a time, at a rate determined by the needs of the customer.

The important thing is to promote continuous flow of products, with the least amount of delay and waiting

The opposite of one-piece flow is large-lot production. Goods produced in large lots build delays into the process .No items can move on to the next process until all items in the lot have been processed .

The larger the lot, the longer the items sit and wait between steps.

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ONE-PIECE FLOW SCHEMATICS

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Operations &Processes

To improve production, it is not enough to improve operations Companies must also improve their processes.

A particular cell is made up of the team members and the equipment that is required to follow the steps in manufacturing of the product.

Improving a process involves streamlining the flow of materials to minimize obstacles and wastes such as:

Time spent in non-value-adding steps

Such as waiting and transport

Downtime caused by changeover and adjustments

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EXAMPLE:

Consider a problem of 4 machines and 6 parts. Try to group them.

Machines 1 2 3 4 5 6

M1 1 1 1

M2 1 1 1

M3 1 1 1

M4 1 1 1

Components

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Machines 2 4 6 1 3 5

M1 1 1 1

M2 1 1 1

M3 1 1 1

M4 1 1 1

Components

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Benefits of Cellular Manufacturing1. Flow times are reduced

2. Saves process time

3. Reduction in inventories

4. Rush orders can be produced without much problems

5. Employees feel empowered & derive job satisfaction

6. Multiple operations get done in a single cell

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Limitations of Cellular Manufacturing1. Issues like placement of bottleneck

machines are need to be addressed during cell formation

2. Machines may require their own individual stocks of materials

3. Inadequacies in employee education, training & involvement could come in the way of proper implementation

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Dividing work into Cells

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CELL DEVELOPMENT

Following points will be covered under this topic : Cluster cells design technique Clustering Schematics CMS Facility Working in a U-shaped Cell Becoming Multiskilled Using Small Flexible Machines Autonomation

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The cell is made up of workers and the equipment required to create the product

The layout of the equipment and the workstations is determined by the logical sequence of production.

Parts are clustered to build part families Part Families visit cells Part Families share set-up ideas and

equipment and follow similar process routing

CLUSTERING TECHNIQUES : -The Fundamental Issue in Cell Development

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Machines are clustered to build cells: Cells lead to Flow Mathematics. Cells contain all equipment needed to produce

apart family Joining machining technologies with tooling

and setup technologies and combining them with people skills and positive management , can all result in a very good manufacturing environment.

Each cell should work towards its own goals and keep contact with other cells to the minimum

CLUSTERING TECHNIQUES : The Fundamental Issue in Cell Development

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Building the CMS Facility

Before Clustering

After Clustering

10/01/14

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Operating In a U-shaped Cell Changing from an operation-based layout to

manufacturing cells will change how people do their work in the factory

In a cell, the equipment and workstations are arranged close together in sequence of processing step

Reduce unnecessary walking and transport to promote flow

The equipment in a cell is laid out in a curved shape The operator’s path is like a U or C These shapes bring the end point of the process

close to the beginning point.

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Multi-Skill aspect of Workers

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Becoming Multiskilled/ Multimachine Operators• Creating a manufacturing cell often changes the

relationship between people and machines in the workplace

• Operators may need to learn how to run different types of equipment to support the process

• In cells where automatic machines are used, most of the operator’s time is spent watching the equipment run

– Such waste is avoided by teaching people to operate several different machines in the process

– Operators can be setting up a workpiece for step 2 while step 1 machine is processing another workpiece

• A cell may be run by one person or several people depending on the size of the cell, cycle times, or production volume.

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'Multi-Functioning' in a Cell

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Cross-Training for Maximum Flexibility• Cross-training enables employees to perform different

functions within a process and lets teams take full responsibility for their processes.

• Operator trained on several machines is qualified to respond to changes in production needs by performing different tasks

– This versatility makes employees more valuable to their teams and to their companies

• Cross-training is a source of employee pride in many workplaces

• Visual display charts are often used to recognize people’s skill attainment in a public way.

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Moving with The Work • Running several machines in sequence

– An operator needs to work standing up rather than sitting down

• To assist one-piece flow manufacturing

– People stand and walk so that work moves smoothly through the process

• Working while standing

– Enables people to respond more quickly if machine problems occur

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Using Small, Flexible Machines

Smaller machines save space Placing them close together reduces walking distance

They are less expensive

Slower machines are appropriate can produce one piece at a time at a speed determined by customer requirements

A cellular manufacturing process may use equipment different from that used in large-lot production

Works best with machines that are smaller and often slower than large-lot equipment

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Using Autonomation (Jidoka) to Eliminate Machine Watching

• Autonomation - an approach to automation that gives equipment “intelligence” so people don’t have to monitor automatic operation

• “Autonomated” machines are semi-automatic machines that autonomously (independently) support one-piece flow processing. Many companies invest in automation because :

– Stop and signal when a cycle is complete or when problems occur

– Often set up to unload automatically after processing

– Do not have to be tended

– People don’t have to perform difficult, dangerous, or repetitive work

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Equipment and workstations arranged close together in sequence of processing steps (U or C)

Relationship between people and machines changes as operators may need to learn how to run different types of equipment to support the process

Machine-watching is avoided by teaching people to operate several different machines

Flexibility to change how people work together in a cell comes from cross-training

Cellular manufacturing works best with smaller and often slower machines

Autonomation (jidoka) is an approach to automation that gives equipment “intelligence” so people don’t have to monitor automatic operation

Summary

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Thank You