FACILITIES PLANNING

Ing. Fernando Corona

04

Manufacturing Cells

Manufacturing Cells

Objectives

To understand what a Manufacturing Cell is and how it canbe implemented.

To be aware of the different variables that must be considered when implementing a Cell.

Manufacturing Cells

1. Layout by tasks vs. Manufacturing Cells

2. Benefits

3. Implementation Requirements

4. Rules for Manufacturing Cells

5. Leader's Responsibilities

6. Manufacturing Cells Implementation

7. Keywords

Contents

Manufacturing Cells

1. Cell: a small part of something; Cellular: adjective.- Something that is made of many small groups that work independently.

2. Manufacturing Cell: A group of equipment (resources), - usually arranged in the shape of a “U” -, which is dedicated to produce similar products or a family of parts.

A Manufacture Cell produces parts, one at a time, following the

sequence of the machines and operations in a lean flow.

Concepts

1. Layouts by Tasks

• Defects in products are not detected until the part has a quality inspection.

• Some of the defects are not generated in the manufacture process but appear due to material handling problems (dirt, spots, damage).

• Parts spend too much time going to all the process. (Sometimes days or weeks – funnel sample).

• Inventory (RM, WIP, and FG), can require up to 25% of the total area of the plant.

vs. Manufacturing Cells

Old “Layouts by Tasks” are inconvenient because:

a) Old configuration by tasks Rockwell Telecommunications sample

b) MC approach Rockwell Telecommunications sample

c) MC new configurationRockwell Telecommunications sample

2. Benefits of Manufacturing Cells

• Defects• Delivery Time• WIP Inventory• FG Inventory• Money invested in

parts. • Throughput Time

Decrease of Increase of

• Inventory Turnover• Productivity• Capacity• Flexibility

2. Benefits of Manufacturing Cells

Teamwork Improvement

• Communication (workers are closer and can help each other)

• Complete understanding of the manufacture process (multitask).

• They have the opportunity to know their customer; talk, discuss and propose improvement.

• Operators are more responsible and have more control in their activities.

• Responsibility of making high quality products from the beginning.

• More satisfaction due to responsibility and variety of the work.

2. Benefits of Manufacturing Cells

Packing Test Assembly

Test

Drill

Assem

bly 1

DieDrill 2Kanban Material

Operators, as a team, decide when to rotate positions

2. Benefits of Manufacturing CellsProductivity

TPM Activities, breaks, meals,

5S´s time, meetings.

Value-Adding Activities

Non Value-Adding Activities, such as:

Unnecessary Motions

Material Handling

Waiting Time

Defects/Re-manufactures

Unnecessary Parts

Too much Inventory

Overproduction

Where does the Productivity Increase come from?

2. Benefits of Manufacturing Cells

Productivity• Productivity is achieved when waste is eliminated.

• Eliminate all “Non Value-Adding Activities”. (because you

have to pay for them).

• Nobody feels good when they realize that half of the time

they are working is dedicated to create waste; such as:

– Transporting

– Searches

– Unnecessary Motions

– Stocking

2. Benefits of Manufacturing Cells

Waste Elimination

1) Overproduction

2) Excessive inventory

3) Over processing

4) Motion

5) Waiting

6) Transportation

7) Defects

* Order tracking (Although not generally recognized as a waste, order tracking in manufacturing operations is quite time- consuming and not a value-added activity)

2. Benefits of Manufacturing Cells

Waste Elimination

3. Implementation Requirements1. Product Families: parts that share the same

manufacturing process and equipment. They are

similar not in shape or size, but because their

process.

2. It is essential that the Cell produces parts or family

parts that the customer constantly requires (20% in

pareto chart).

3. Small and Easy to move equipment.

4. Flexible and Multi-task workers.

5. Additional Capacity. (Reserved)

4. Rules for Manufacturing Cells1. When installing a Manufacturing Cell, the productivity will

increase, so prepare a plan and explain to the personnel that some of them will have to be “Re-located”

2. Design a complete Inspection System for each Manufacturing Cell.

3. Each aspect affected by the Manufacturing Cell should be discussed and communicated to all the workers and the Labor Union through the Manager.

4. The design for the Cell should consider: - Work Flow- Parts and Material Flow- 5S´s

5. Leader's Responsibilities

Develop a clear understanding of the global vision of the company.

Give a clear explanation of the idea of the Manufacturing Cell.

Clear understanding of the implementation process.

Visit some other plants (competence if possible).

Lead the first Pilot Cell

6. Manufacturing Cell Implementation

STEP 1. Winner Work Team Selection/Pilot Cell Selection

STEP 2. Determine Product Families

STEP 3. Product Grouping Analysis

STEP 4. Determine Production Capacity

STEP 5. Compare customer’s demand VS capacity.

STEP 6. Cell Design, Cell Layout.

STEP 7. Standardize operations by documenting processes.

6. Manufacturing Cell Implementation

STEP 1a. Pilot Cell Selection

A key point for the success and implementation's speed is the selection of the Team and the Team leader.

Enthusiasm and Leadership: supported by the Management.

Manufacturing Cells represent a drastic change, but changes are required to achieve the company's goals.

Team Leader: Must have understanding of: The Team, Production and Planning… Someone that the personnel admires and respects.

• It is important to make sure you have a successful launching of your Pilot Cell; This will be a good “sign” for

the company and for the future of the Cells Project.

6. Manufacturing Cell Implementation

STEP 1b. Team Selection (decision group)

• 5 to 12 members

• At least 2 operators of the selected process.

• Maintenance Staff (Skills and Authority).

• Process Engineers.

• Quality Engineers.

• Supervisors.

• Accounting rep. (desirable)

• Human Resources/Training Staff

6. Manufacturing Cell Implementation

STEP 2. Determine Product Families

• Parts in development must be included.

• The Team must check meticulously to make sure no part is left behind.

• If there are alternative part production routes, they must be included.

• Use Product Families selection formats.

Include all Active Part Numbers

6. Manufacturing Cell Implementation

STEP 3. Product Grouping Analysis

Purpose: To group the Part Numbers by similar equipment routes.

• When all Parts with similar routes are in a group, make a chart like this:

Lateral Support

Medium Support

Front Support

Lateral “C” Support

Left Support

SKU’s Description Tasks

6. Manufacturing Cell Implementation

STEP 4. Determine Production Capacity

Purpose: To determine Production Capacity including Change-over Time of each one of the Parts.

• Product Families Selection must be done previously.

• Must take note of all obvious wastes on the Time Study Sheet.

• Wastes must be eliminated before or during the Manufacturing Cell development process.

6. Manufacturing Cell Implementation

STEP 5. Compare customer’s demand vs. capacity.

Purpose: To compare the Cell's production capacity (step 4) with your customer’s demand.

• The point is to design cells where you can balance the work, a cell must be balanced efficiently.

• At this point, it is important to search for all bottle-necks.

6. Manufacturing Cell Implementation

STEP 6. Cell Design, Cell Layout.

Purpose: To have a lean and productive cell, avoiding all kinds of waste in order to satisfy the demand and increase your profit.

Cell Layout must be carefully planned taking in consideration each machine specification, the product flow process, moves etc.

STEP 7. Standardize operations by documenting processes.

6. Manufacturing Cell Implementation

Purpose: To ensure a continuous process in order to make successful further Cell implementation.

Documenting helps saving time, maintains knowledge as it should be and is necessary for ISO and other certifications.

KeytermsManufacturing Cells

Pilot Cell Manufacturing Cell Production Capacity

Part Number (SKU)

Part Change-over Time

Product Family

Waste

7 must common types of waste (mudas)