Cellular

Layout
Presented By


Vikash Shaw
Cellular Layout
•
•In a cellular layout the design is not according to the
functional characteristics of equipment, but rather by
self-contained groups of equipment (called cells),
needed for producing a particular set of goods or
services.
•Group technology, or cellular manufacturing, classifies
parts into families so that efficient mass-production-
type layouts can be designed for the families of
goods or services.
•Cellular layouts are used to centralize people expertise
and equipment capability.
 Cellular Manufacturing
 Workstations are arranged in a sequence that
 supports a smooth flow of materials and steps

through the process, with minimal transport or
delay
Cellular Manufacturing
Layout
Typ e s o f W a ste
• Defects -scrap, rework, inspection
• Waiting -personnel downtime
• Processing -unnecessary, incorrect
• Overproduction-compared to the next step
• Movement -up & down, unnecessary
• Inventory -raw, WIP, finished goods
• Transport -long distance, inefficiency
• Knowledge -lost ideas, improvements, poor
 utilization of skills
O n e Pie ce Flo w
 • …is a condition that exists when products
move through process steps one unit at a time
- “make one, move one”


 • The opposite of one piece flow is mass

production with batches and queues
One Piece Flow Creates.
 • Quicker delivery


• Reduction in storage and

Transportation

• Less damage, deterioration, or

Obsolescence

• Many other waste savings:

inventory, waiting,

overproduction, defects


WASTE ELIMINATION FREES CAPACITY
Pro ce sse s
There are 4 basic manufacturing processes:
• Transformation: assembly, disassembly, change

of shape or quality.
• Inspection: comparison with a standard.

• Transport: change of location.

• Storage: a waiting period when nothing else is

happening
NOTE: All the processes add time and cost. Only the

transformation step adds value to the product.

Typical manufacturing cell
Operating in a Cell
Operating in a Cell
• Reduce travel distance

by arranging

equipment and

workstations closer

together.

• Beginning of process is
closer to end of

process….minimizes

the travel distance for

next cycle.

input output
Input
Output
Working in a cell
Work Cells - Some
Advantages
Reduced work-in-process inventory
Less floor space required
Reduced raw material and finished
goods inventories required
Reduced direct labor costs
Heightened sense of employee
participation
Increased utilization of equipment
machinery
Reduced investment in machinery and
equipment
 Basic Elements of Cell
Design

Phase 1: Understanding the Current

Conditions

Phase 2: Converting to a Cellular Layout

Phase 3: Continuously Improving the Process
Understanding the Current
Conditions

The basic steps to understanding the current

conditions:
– Collect Product and Production Data

– Document Current Layout and Flow

– Time the Process

– Calculate Process Capacity

– Create Standard Work Combination Chart

Phase 2: Converting to a
Cellular Layout

Brainstorm to improve 4 basic elements of

production:-
• Method

• Machines

• Materials

• People
Plan Possible Layouts
– Use the process sequence as basic principle.

– Place everything as close together as

possible without
 crowding.
Move the Machines

– For a smooth transition, team needs to

discuss with
production, maintenance, transport, and

engineering.
Document the New Operating Procedures

– Revise the Standard Work to show new

layout and the

amount of WIP.
Phase 3: Continuously Improving the
Process

Formation of the cell is not the end point; rather

it is the beginning of continuous improvement.
Common Improvement targets:

– Long cycle times

– Product defects

– Long change over times

– Equipment failures



Thanking
You…..

For spending your valuable time with us