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Cellular Manufacturing
Sections: 1. Part Families 2. Parts Classification and Coding 3. Production Flow Analysis 4. Cellular Manufacturing 5. Applications in Group Technology 6. Quantitative Analysis in Cellular Manufacturing GT
Recap
Define Relation with lay out Types
Visual Coding PFA
Cellular Manufacturing
Application of group technology in which dissimilar machines or processes are aggregated into cells, each of which is dedicated to the production of a part family or limited group of families Typical objectives of cellular manufacturing:
To shorten manufacturing lead times To reduce WIP To improve quality To simplify production scheduling To reduce setup times
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2. Multiple machines with semi-integrated handling 3. Automated cell automated processing and integrated handling
Flexible manufacturing cell Flexible manufacturing system
Rectangular layout also allows variations in part routing and allows for return of work carriers if they are used
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Process planning and production scheduling are simplified Work-in-process and manufacturing lead time are reduced Improved worker satisfaction in a GT cell Higher quality work
Simplification and standardization of design parameters such as tolerances, chamfers, hole sizes, thread sizes, etc.
Reduces tooling and fastener requirements in manufacturing
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Q g i t c f n M r a u l e C s y A v
CMS and its relationship to Job and Flow Shops: We can define the movement in a Job Shop (mathematically) this way for any product i:
Grouping parts and machines by Rank Order Clustering Arranging machines in a GT Cell
In developing CMS manufacturing systems we are trying to make all part flows act like Flow shop mathematics!
N t s e k r w l a o i t c n u f W M m w c u d f l b n o p r m a e t s i h
N O a M C s i 1 p e t S : E T g G F M N A E L o i c l t e m a d n u f
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Benefits of GT and CMS (Companies Reporting): 52 % Report reduction in new part design 1 0 % Report reduction in #of new drawings thru standardization 3 0 % Report reduction in new shop drawings 6 0 % Report reduction in IE time 2 0 % Report reduction in floor space 45 % Report reduced scrap 8 % 0 Report reduced production and quality costs 6 9 % Report reduced set-up time (cost)
N T G f v u s i n a m c y b d r p R : e t o
Benefits of GT and CMS (Companies Reporting): 7 0 % Report reduced throughput time (even more report better predictability of delivery) 8 2 % Report reduced numbers of overdue orders 42 % Report reduced raw-materials inventory 62 % Report reduced WIP 6 0 % Report reduced finished goods inventory 33 % Report increased employee output/time unit (productivity improvement)
Clustering Techniques: the Fundamental Issue in Cell Development We cluster parts to build part families
Part Families visit cells Part Families share set-up ideas and equipment (Family Fixtures) Part Families follow the same (or similar) process routing These are the ideas and activities that offer reported benefits
B g n i t s u l C r o f e
A g n i s u l C r e t f
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Recap
GT
Define Relation with lay out Types
Visual Coding PFA Clustering Method
Process Similarity methods Rank Order Method
Clustering Methods
Using Process Similarity methods:
Create Machine Part Matrices Compute machine pair wise Similarity Coefficient comparisons:
S ij
here :
x ij
Q g c f M r C s y l A e v i t n a u
ij
x jj
Example:
P a r e b m u N t X A B C D E 1 1 1 1 1 1
M ID e n i h c a
3 1 1
1 1 1
1 .33 1 2 0 S AC 0 04 2 S AD .67 2 1 S AB
Continuing:
0 0 05 0 S BC 0 04 2 S BD .67 2 1 0 S BE 0 0 5 0 SCD 0 05 2 SCE .67 2 1 0 S DE 0 06 S AE
Continuing:
Examining our Matrix and our freshly clustered machine cells, we develop 2 part families:
For the Cell A/D/B: Part Numbers 2, 3 & 5 For the Cell C/E: Part Numbers 1, 4 & 6
Here, if the similarity coefficient is > 0.33 consider clustering This criteria means clustering:
A&D, A&B, B&D C&E
De-clustering:
A&C, A&E, B&C, B&E and C&D, D&E
Care must be taken (in most cases) to assure that each cell has all the machines it needs sometimes a couple of families need a key machine
In this case, the manager must decide to either replicate the common machine or share it between the cells creating a bottleneck and scheduling problem for each cell This is typically one of the cost problems in CMS systems
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3 1 1
5 1
1 1 1
Step 1:
B .W . T
Step 3:
P a r e b m u N t
1 1 1 1 1 1 1 1 24+23 = 24 1 22+21=6 5 22+21+2 0=7 4 24+23= 24 2 1 22+20= 5 6 2 4= 1 6 3 2 3 4 1 1 1 5 6 1 D.E q u i v R k n a E C 24 23 22 21 20
P a r s e b m u N t
1 B .W : t A B C D E 1 1 1 1 1 1 25 2 24 3 23 1 1 1 1 1 4 22 5 21 1 6 20
M ID e n i h c a
D B A
5 4 2 3 1 D.E q u v i R k n a
S 2:M p e t ! d r o e R t s u
M ID e n i h c a
S 4:M p e t d r o e R t s u
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! R s u l C t a e r Back at Step 1: G
Issues in Clustering:
D.E q v R k n a
P a r e b m u N t
1 B : t W E C 25 1 1 4 24 1 1 1 1 1 1 1 1 1 6 23 1 3 22 2 21 5 20
R/O clustering oscillations indicating need of machine replication (happens often!) Presence of Outliers and/or Voids in the finished clusters
Outliers indicate the need of machine replication Voids indicate skippedmachines in a cell
1 2 3 4 5
D B A
Generally speaking, these clustering algorithms are designed to convert existing routes for facility reorganization
They require a previous engineering study to be performed to develop a series of routers on a core sample of parts that represent most of the production in the shop
Alternative means to Develop Cells/Families: Most often companies rely on Classification and Coding (C&C) systems for analyzing their part mix These codes can be general purpose or company specific
General Purpose:
Opitz is a german developed code for machined parts (see over) KC1, KC2 and KK1 systems Japanese government lab based codes for machined parts Brish a british developed code for general material use Foundry codes have been developed by several groups (see Lindeke & Rubinovich, 19 8 7 in USA)
M ID e n i h c a
O P! O T S : m h y a t s e d r
T zp O t e d c m r o F s i h t r a p e k i l f s h n u S d o C
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Fixturing
Fixturing is a means to speed up part loading and increase accuracy of machine and mfg. processes These are tools that:
Locate the work for geometric control of various DOF May also provide a means to guide the tooling used to perform the operations (Jigs ) Before being used these tool must be accurately placed on the machine often a time consuming task since their placement tolerance must be 10x better than part tolerance!
Fixturing
In CMS, it is often possible to build Family Fixtures These are fixtures that can be shared among all the parts in the family (because they are similar geometrically and by mfg. process) thus reducing time to set-up any part in the family The Family Fixture is generic and may (likely) require the addition of specific change pieces for different members of the family but definitely not different fixtures.
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Fixturing Conventional fixturing means a separate fixture for each part made Family fixturing means a separate fixture for each family made (but several adaptors for individuals in the family) Typically, Family Fixtures cost more than conventional fixtures so lets do a cost analysis
Conventional Fixturing
Facility Tool Costs:
P
Ctools Cwi
i 1
P =n l g i d s t a p f o r e b m u
where
C ; t o c n g e d s i ; o c l r e t a m s C ; n o t c r b a f s i C ; c y r o t e v n s i C t o c g l d n a h s i C di m f i h
Cwi Cd Cm C f Ci Ch
leads to unit tooling cost/part:
P
C
Cutools
i 1
wi
n =l (s d s a p o r b u n m t e f i .) t
Pn
Family Fixturing:
Cell Tooling Cost:
Q
Example:
C l a i t e v n o M l o T n i a R .500 s 1 p / a t r N A N A 400 3b a / h c t y r /3 y s r =3600 G d I T e a s R 1 . s 000 1 y l i m a r o f R 1 . s 00 .85/p a t r 400 3b a / h c t y r /3 y s r =3600
Ctools CFF Ca (i )
i 1
Q =n y l F i s t a p f o r e b m u
#F .R q e u d e r i C r p a d A t s o
C ;m t o c n g e d s i ; o c l r e t a m s i C ; n o t c r b a f s i C ; c y r o t e v n s i C t o c g l d n a h s i C d f i h N .A o q e R s r o t p a d r T z S e d r O l a c i p y e
Cu
Ctool Qn
T /li h t B l a c i p y e f m t n =l (s d y p h c a o r b u n m t e f i .) t
Family Fixturing:
N .P o a r s t 1 2 3 20 C .T s l o R .500 s R 1 . s 000 R 1 . s 500 R 1 . s 0000 U s o C t i n 500/3600 =. 1 39 1 000/7200=. 1 39 1 500/ 1 0800=. 1 39 1 0000/72000=. 1 39 G s l o T R 1 . s 085* R 1 . s 1 70 R 1 . s 255 R .2700 s U s o C t i n 1 085/3600=.30 1 (.278) 1 70/7200=. 1 63 (. 1 53) 1 255/ 1 0800=. 1 1 6 (. 1 1 ) 2700/72000 = .038
Family Fixturing:
Earlier we found the text author stating that the cost of inventory in a batch is independent of schedule here we see this may not be the case! In a cell, setting up the family fixture is time consuming but changing between family members is quick and easy only the time to remove an adaptor and addition of a new one (or not!) This leads to the second rung of the factory with a future SMED if scheduling is rational in the cells!
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Recap
GT
Define Relation with lay out Types
Visual Coding PFA Clustering Method
Process Similarity methods Rank Order Method
Q g c f M r C s y l A e v i t n a u
FMS CAPP
It must be possible to group a portion of the parts made in the plant into part families
The part similarities allow them to be processed on the FMS workstations
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A l C g i r c f n M d e a m o t u
Automated manufacturing cell with two machine tools and robot. Is it a flexible cell?
Types of FMS
Kinds of operations
Processing vs. assembly Type of processing
If machining, rotational vs. non-rotational
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A two-machine flexible manufacturing cell for machining (photo courtesy of Cincinnati Milacron)
A five-machine flexible manufacturing system for machining (photo courtesy of Cincinnati Milacron)
2. Random-order FMS
Appropriate for large part families New part designs will be introduced Production schedule is subject to daily changes
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FMS Components
Workstations Material handling and storage system Computer control system Human labor
Workstations
Load and unload station(s)
Factory interface with FMS Manual or automated Includes communication interface with worker to specify parts to load, fixtures needed, etc.
Assembly machines
Temporary storage Convenient access for loading and unloading Compatibility with computer control
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Straight line flow, well-defined processing sequence similar for all work units Work flow is from left to right through the same workstations No secondary handling system
Linear transfer system with secondary parts handling system at each workstation to facilitate flow in two directions
One direction flow, but variations in processing sequence possible for different part types Secondary handling system at each workstation
Rectangular layout allows recirculation of pallets back to the first station in the sequence after unloading at the final station
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Robot-Centered Cell
Suited to the handling of rotational parts and turning operations
3. Production control
Product mix, machine scheduling, and other planning functions
5. Shuttle control
Coordination of secondary handling system with primary handling system
6. Workpiece monitoring
Monitoring the status of each part in the system
9 . Diagnostics
Diagnose malfunction causes and recommend repairs
FMS Applications
Machining most common application of FMS technology Assembly Inspection Sheet metal processing (punching, shearing, bending, and forming) Forging
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FMS Benefits
Increased machine utilization
Reasons:
24 hour operation likely to justify investment Automatic tool changing Automatic pallet changing at stations Queues of parts at stations to maximize utilization Dynamic scheduling of production to account for changes in demand
FMS Benefits
Greater responsiveness to change Reduced inventory requirements
Different parts produced continuously rather than in batches
Lower manufacturing lead times Reduced labor requirements Higher productivity Opportunity for unattended production
Machines run overnight ("lights out operation")
Processing requirements
Determine types of processing equipment required
Types of workstations Variations in process routings Work-in-process and storage capacity Tooling Pallet fixtures
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Tool management
When to change tools
Machine loading
Deciding what operations and associated tooling at each workstation
Part routing
Selecting routes to be followed by each part
Parameters
Deterministic models
1. Bottleneck model - estimates of production rate, utilization, and other measures for a given product mix 2. Extended bottleneck model - adds work-in-process feature to basic model
Design Principle
Algorithm used for calculating the throughput (X) of the material-handling device (MHD) based on Mean Value Analysis. (p.70 3) Assumption:S HD M e h r f w c s n o i a t
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Results
Adaptive Neuro-Fuzzy System (ANFS) network - Fuzzy toolbox in MATLAB used for approximating Tr, X and Wr. - The performance measures are found by varying different system parameters: C, , N and S. - Using these parameters as inputs, an ANFS network was built. - ANFS measure values serve as a comparison for the analytical values calculated using MVA. - Fix set of Homogeneous and Heterogeneous processing times for fuzzy and MVA measurements:
Results Cont.
Parameters: N=24,S=15, Q=5 As the number of MHD (C) increases, the throughput (X) and average time (Wr) decreases.
Results Cont.
Parameters: N=24, =15, Q=5
Effect of S on X and Wr for C=1 and C=5 X and Wr increase with increasing S. However, for heterogeneous processing time these take lower values in comparison to the homogeneous one. Both X and Wr are larger for C=1 compared to C=5
Results Cont.
Parameters: S=15, =0 .25, Q=5
- As N increases, both X and Wr decrease - For homogeneous values of processing time these take the higher value in comparison to the heterogeneous one
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Results Cont.
- Result of mean service time (Tr) and (Wr) by varying the move time multiplier (). - As increases, Tr increases linearly - The waiting time (Wr) increases exponentially as also increases.
CAPP
P R O C P S E L A N IG
Process Planning is that Function Within a Manufacturing Facility that Establishes which Machining Processes & Parameters are to be Used (As Well As Those Machines Capable Of Performing These Processes) To Convert (Machine) A Piece Part From Its Initial Form To A Final Form Predetermined (Usually By A Design Engineer) From An Engineering Drawing. (i.e. The Preparation of the Detailed Work Instructions to Produce a Part) Pr o c e d r b g i n a l p s m g i r t c f u n a B e g d i r
De s n g i
M g i r t c f u n a
20
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1 .P R E P A R A V F O E G S Y R T A R A I N P T R O C P S E L A N IG
P a r Dr t a w g n i
C g n i d o
F m a e n O y l i
S r d n a t Pl a n F e l i
F m a n t r o F y l i
(In d e x e d b y l i m a F M x) i r t a
Pr o c e Pl s a n
2. P R O D U C O T V F E G A S N A R A I N P S E C O R T L A N IG
C g n i d o
F m a h c r e S y l i
S d r n a t Pl a n F e l i
Pr o c e Pl s a n
E g n t i d
S Pl r d n a t a n R l a v i r t e
2 1
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