Cellular Manufacturing

CELLULAR
MANUFACTURING
By:
Chintan H.Trivedi
M.Tech 1st Sem
RCOEM
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
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.
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.
Traditional
VS.
U-shaped
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 onepiece 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 .
ONE-PIECE FLOW SCHEMATICS
Operations
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.
Processes
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
EXAMPLE:
Consider a problem of 4 machines and 6 parts. Try to
group them.
Components
Machines
M1
M2
M3
M4
Components
Machines
M1
M2
M3
M4
Benefits of Cellular Manufacturing
Flow times are reduced
Saves process time
Reduction in inventories
Rush orders can be produced without much problems
Employees feel empowered & derive job satisfaction
Multiple operations get done in a single cell
Limitations of Cellular Manufacturing
Issues like placement of bottleneck machines are need

to be addressed during cell formation
Machines may require their own individual stocks of

materials.
Inadequacies in employee education, training &

involvement could come in the way of proper
implementation
Dividing work into Cells
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
CLUSTERING TECHNIQUES :
The Fundamental Issue in Cell Development
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
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
Building the CMS Facility
Before
Clustering
After
Clustering
10/01/14
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 operators path is like a U or C
These shapes bring the end point of the process close to
the beginning point.
Multi-Skill aspect of Workers
21
21
Becoming Multi-skilled/ Multi-machine

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.
A cell may be run by one person or several people

depending on the size of the cell, cycle times, or
production volume.
Becoming Multi-skilled/ Multi-machine

Operators
In cells where automatic machines are used, most

of the operators 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
'Multi-Functioning' in a Cell
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
Visual display charts are often used to recognize

peoples skill attainment in a public way.
Moving with The Work
Running several machines in sequence
To assist one-piece flow manufacturing
An operator needs to work standing up rather than

sitting down
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
Using Small, Flexible Machines

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
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
Using Autonomation (Jidoka) to Eliminate

Machine Watching
Autonomation - an approach to automation that gives
equipment intelligence so people dont 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
People dont have to perform difficult, dangerous, or
repetitive work
Summary
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
Summary
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 dont have to
monitor automatic operation
Thank
You!

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CELLULAR

Introduction & Concept

The goal of cellular

The opposite of onepiece flow is large-lot

ONE-PIECE FLOW SCHEMATICS

To improve production, it is not enough to improve

A particular cell is made up of the team members and

Time spent in non-value-adding steps

Benefits of Cellular Manufacturing

Flow times are reduced

Saves process time

Rush orders can be produced without much problems

Employees feel empowered & derive job satisfaction

Multiple operations get done in a single cell

Limitations of Cellular Manufacturing

Issues like placement of bottleneck machines are need

Machines may require their own individual stocks of

Inadequacies in employee education, training &

Dividing work into Cells

Using Small Flexible Machines

Building the CMS Facility

Operating In a U-shaped Cell

Multi-Skill aspect of Workers

Becoming Multi-skilled/ Multi-machine

Creating a manufacturing cell often changes the

Operators may need to learn how to run different types

A cell may be run by one person or several people

Becoming Multi-skilled/ Multi-machine

In cells where automatic machines are used, most

Such waste is avoided by teaching people to

Operators can be setting up a workpiece for step

Cross-Training for Maximum Flexibility

Cross-training enables employees to perform different

Operator trained on several machines is qualified to

This versatility makes employees more valuable to their

Visual display charts are often used to recognize

Moving with The Work

Running several machines in sequence

To assist one-piece flow manufacturing

An operator needs to work standing up rather than

People stand and walk so that work moves

Working while standing

Enables people to respond more quickly if machine

Using Small, Flexible Machines

They are less expensive

Slower machines are appropriate can produce one

Using Autonomation (Jidoka) to Eliminate

Equipment and workstations arranged close together in

Relationship between people and machines changes as

Machine-watching is avoided by teaching people to operate

Flexibility to change how people work together in a cell comes

Cellular manufacturing works best with smaller and often

Autonomation (jidoka) is an approach to automation that

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