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CHAPTER- 7
CELLULAR MANUFACTURING SYSTEMS
Chapter-7 includes:
7.1 Part Families,
7.2 Parts Classification and Coding,
7.3 Features of Parts Classification and Coding Systems, Opitz
7.4 Parts Classification and Coding Systems,
7.5 Composite Part Concept,
7.6 Machine Cell Design,
7.7 Applications Of Group Technology,
7.8 Production Flow Analysis,
7.9 Quantitative analysis of Cellular Manufacturing,
- Grouping of parts and Machines by Rank Order Clustering,
- Arranging Machines in a GT Cell.
7. CELLULAR MANUFACTURING SYSTEMS
• Cellular manufacturing is an application of Group Technology in manufacturing,
in which the production equipment is grouped into machine cells, where each
cell specializes in the production of a part family.
• A manufacturing cell is a cluster of machines or processes located in close
proximity and dedicated to the manufacture of a family of parts.
• The parts are similar in their processing requirements, such as operations,
tolerances and machine tool capacities.
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
GROUP TECHNOLOGY
Group technology (abbreviated GT) is a manufacturing philosophy in which similar
parts are identified and grouped together to take the advantage of their similarities
in manufacturing and design.
 A manufacturing philosophy in which similar parts are identified and grouped
together to take advantage of their similarities in design and production.

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 Similarities among parts permit them to be classified into part families.

 In each part family, processing steps are similar.
 The improvement is typically achieved by organizing the production facilities
into manufacturing cells that specialize in production of certain part families.
OVERVIEW OF GROUP TECHNOLOGY
 Parts in the medium production quantity range are usually made in batches.
 Disadvantages of batch production:
 Downtime for changeovers.
 High inventory carrying costs.
 GT minimizes these disadvantages by recognizing that although the parts are
different, there are groups of parts that possess similarities.
PART FAMILIES AND CELLULAR MANUFACTURING
 GT exploits the part similarities by utilizing similar processes and tooling to
produce them.
 Machines are grouped into cells, each cell specializing in the production
of a part family, called cellular manufacturing
 Cellular manufacturing can be implemented by manual or automated methods.
 When automated, the term flexible manufacturing system is often
applied.
When to Use GT and Cellular Manufacturing?
1. The plant currently uses traditional batch production and a process type
layout: these results in much material handling effort, high in-process
inventory, and long manufacturing lead times.
2. The parts can be grouped into part families: A necessary condition to apply
group technology Each machine cell is designed to produce a given part family,
or a limited collection of part families, so it must be possible to group parts
made in the plant into families.
CMS and Group Technology (GT)

NOTE: Step 1 is CMS – a fundamental actionPage 2

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PROBLEMS IN IMPLEMENTING GT
1. Identifying the part families: Reviewing all of the parts made in the plant and
grouping them into part families is a substantial task.
2. Rearranging production machines into GT cells: It is time-consuming and costly
to physically rearrange the machines into cells, and the machines are not
producing during the changeover.
7.1 PART FAMILY
A part family is a collection of parts which are similar either because of geometric
shape and size or because of similar processing steps that are required in their
manufacturing. The parts within a family are different, but their similarities are close
enough to merit their identification as members of the part family.
Geometric Similarities

Figure (a) is a rotational part involving turning and drilling operations.

Figure (b) is also a rotational part involving turning and milling operations.
Figure (c) is a round cast part involving only bore turning operation.
Figure (d) is a round part involving external threading operation.
Thus all these four work parts can be manufactured in a manufacturing cell having
Turning Lathe, Drill press, and a Milling machine.
Considering the similarities in these four work parts they can be
classified into a typical part family.
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PART FAMILY

Ten parts are different in size, shape, and material, but quite similar in terms of
manufacturing. All parts are machined from cylindrical stock by turning; some parts
require drilling and/or milling.
TRADITIONAL PROCESS LAYOUT

Similar machines grouped together

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PROCESS LAYOUT

Figure shows a process-type Layout for batch production in a machine shop. The
various machine tools are arranged by function. There is a lathe section, milling
section, drill press section, and so on. During the machining of a given part, the work
piece must be moved between sections, with perhaps the same section being visited
several times.
This results in significant amount of material handling, a large in-process inventory,
usually more setups than necessary, long manufacturing lead times, and high cost.
CELLULAR LAYOUT BASED ON GT

Each cell specializes in producing one or a limited number of part families.

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7.1 PART FAMILY

In parts classification and coding, similarities among parts are identified,
and these similarities are related in a coding system.
Two categories of part similarities can be distinguished:
(1) Design attributes, which are concerned with part characteristics such as
geometry, size, and material;
(2) Manufacturing attributes, which consider the sequence of processing steps
required to make a part.
A number of classification and coding systems are available.
However, none of the systems has been universally adopted.
One of the reasons for this is, a system that is best for one company may not be best
for another company.
REASONS FOR USING CODING SCHEME
Reasons for using a coding scheme include:
Design retrieval: A designer faced with the task of developing a new part can use a
design retrieval system to determine if a similar part already exists.
A simple change in an existing part would take much less time than designing a whole
new part from scratch.
Automated process planning: The part code for a new part can be used to search for
process plans for existing parts with identical or similar codes.
Machine cell design: The part codes can be used to design machine cells capable of
producing all members of a particular part family, using the composite part concept.
7.3 FEATURES OF PARTS CLASSIFICATION AND CODING SYSTEMS
The principal functional areas that utilize a parts classification and coding system are
Design and manufacturing.
Accordingly, parts classification systems fall into one of three categories:
1. Systems based on part design attributes
2. Systems based on part manufacturing attribute
3. Systems based on both design and manufacturing attributes
A certain amount of overlap exists between design and manufacturing attributes,
since a part's geometry is largely determined by the sequence of manufacturing
processes performed on it.
There are three structures used in classification and coding schemes:
1. Hierarchical Structure: also known as a mono code, in which the interpretation of
each successive symbol (digit) depends on the value of the preceding symbols (digit).
2. Chain type structure: also known as a poly code, in which the interpretation of
each symbol in the sequence is always the same; it does not depend on the value of
preceding symbols.
3. mixed-mode structure: which is a hybrid of the two previous codes.

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DESIGN AND MANUFACTURING ATTRIBUTES

PARTS CODING SYSTEMS

Three parts classification and coding systems which are widely recognized among
people familiar with GT are:
1. OPITZ system
2. MICLASS system
3. KK3 system
7.4 OPITZ PARTS CLASSIFICATION AND CODING SYSTEM
This parts classification and coding system was developed by H.Opitz of the
University of Aachen in West Germany.
The Opitz coding system uses the following digit sequence:
12345 6789 ABCD
The basic code consists of nine digits, which can be extended by adding four more
digits. The first nine digits are intended to convey both design and manufacturing
data. The five digits 12345, are called the “form code” or “primary code”
and describe the primary design attributes of the part.
The next four digits, 6789, constitute the “supplementary code”. It includes some of
the attributes that would be of use to manufacturing (dimensions, work material,
starting raw work piece shape and accuracy).
The extra four digits, ABCD, are referred to as the “secondary code”
and are intended to identify the production operation type and sequence.
The secondary code can be designed by the firm to serve its own particular needs.

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OPITZ PARTS CODING SYSTEM

Determine the form code (first five digits) in the Opitz system for the part shown in
figure. Assume the following dimensions for the part: Overall length = 5 in., large
outside diameter (OD) = 1.0 in., small outside diameter (od) = 0.5 in., length of small
od on either side = 2.0 in. Use the form code in Figure 12.6.

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7.5 COMPOSITE PART CONCEPT

• A composite part for a given family is a hypothetical part that includes all of
the design and manufacturing attributes of the family
• In general, an individual part in the family will have some of the features of the
family, but not all of them
• A production cell for the part family would consist of those machines required
to make the composite part
• Such a cell would be able to produce any family member, by omitting
operations corresponding to features not possessed by that part

• Part families are defined by the fact that their members have similar
design and manufacturing attributes. The composite part concept conceives of
a hypothetical part that represents all of the design and corresponding
manufacturing attributes possessed by the various individuals in the family.
• For example, the composite part shown in figure is a rotational part made up
of seven separate designs and manufacturing features.
• A part with all seven attributes, such as composite part would go through all
seven steps.
• For part designs without all features, unneeded operations are simply being
cancelled. A machine cell would be designed to provide all machining
capabilities to produce the composite part. The composite part would go
through all processing steps. The composite part concept is useful for
visualizing the machine cell design problem.

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7.6 MACHINE CELL DESIGN

The GT machine cell is designed on the composite part concept. A hypothetical part is
assumed to have all the design and manufacturing attributes of various members of
the part family, which is called composite part and the process capabilities are
planned such that the composite part can be produced. Then any member of the part
family can be produced from the available process capabilities since, no member of
the part family would not have all the features of the composite part. Now the group
of machines that can produce the composite part is called GT machine cell.
EXAMINING A CELL IN THE CMS:

Notice MW or ‘multi-functional’ workers – this team is responsible for

all production within their cell.
CELL WITH SEMI-INTEGRATED HANDLING: U-SHAPED LAYOUT

U-shaped machine cell with manual part handling between machines

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CELL WITH SEMI-INTEGRATED HANDLING: IN-LINE LAYOUT

In-line layout using mechanized work handling between machines

CELL WITH SEMI-INTEGRATED HANDLING: LOOP LAYOUT

Loop layout allows variations in part routing between machines

CELL WITH SEMI-INTEGRATED HANDLING: RECTANGULAR LAYOUT

Rectangular layout also allows variations in part routing and allows for
return of work carriers if they are used.
FOUR TYPES OF PART MOVES IN MIXED MODEL PRODUCTION SYSTEM

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KEY MACHINE CONCEPT

Applies in cells when there is one machine (the key machine) that is more expensive
or performs certain critical operations. Other machines in the cell are supporting
machines. Important to maintain high utilization of key machine, even if this means
lower utilization of supporting machines.
7.7 APPLICATIONS OF GT
Application of Group technology in the following areas:
1. Product design
2. Tooling and setups
3. Material handling
4. Production and inventory control
5. Employee satisfaction
6. Process planning procedures
1. GT IN PRODUCT DESIGN
The benefits of GT in design are:
• Use of automated design-retrieval system helps to eliminate design
duplication.
• Improves cost estimating procedures and helps to promote design
standardization.
• Design features such as inside corner radii, chamfers, and tolerances are most
likely to become standardized with group technology.
2. GT IN TOOLING AND SETUP
• Group technology promotes standardization of tooling and setups.
• In tooling, an effort is made to design jigs and fixtures that will accommodate
every member of a part’s family.
• Work holding devices are designed to use special adaptors which convert the
general fixture into one that can accept each part family member.
• The machine tools in GT cell do not require drastic changeovers in setups
because of the similarity in the work parts processed on them. Hence, setup
time is saved.
3. GT IN MATERIAL HANDLING
Another advantage in manufacturing is a reduction in the work part move and
waiting time.
The group technology machine layouts lend themselves to effective flow of materials
through the shop.

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4. GT IN PRODUCTION AND INVENTORY CONTROL

• Production scheduling is simplified with group technology. In effect, grouping
of machines in to cells reduces the number of production centers that must be
scheduled.
• Grouping of parts into families reduces the complexity and size of the parts
scheduling problem.
• Setups, production lead times, work-in-process; late deliveries can all be
reduced besides more efficient material handling.
• Thus for a typical GT cell for example, as much as 70% reduction in production
time, 62% reduction in work-in-process inventories and 82% reduction in
overdue orders may be recorded.
5. GT IN EMPLOYEE SATISFACTION
• The machine cell often allows parts to be processed from raw material to
finished state by a small group of workers.
• The workers are able to visualize their contributions to the firm more clearly.
• This tends to cultivate an improved worker attitude and a higher level of job
satisfaction.
6. GT IN PROCESS PLANNING PROCEDURES
• The time and cost of the process planning function can be reduced through
standardization associated with group technology.
• A new part design is identified by its code number as belonging to a certain
part’s family, for which the general process routing is known.
• The logic of this procedure can be written into computer software to form a
computer automated process planning system.
BENEFITS OF GROUP TECHNOLOGY IN MANUFACTURING
• Standardization of tooling, fixtures, and setups is encouraged
• Material handling is reduced
• Parts are moved within a machine cell rather than the entire factory
• 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

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7.8 PRODUCTION FLOW ANALYSIS

Production flow analysis (PFA) is a method for identifying part families and
associated machine groupings that uses the information contained in production
route sheets rather than on part drawings. Work parts with identical or similar
routings are classified into part families. These families can then be used to form
logical machine cells in a group technology layout.
The procedure in production flow analysis must begin by defining the scope of the
study, which means deciding on the population of parts to be analyzed.
Should all of the parts in the shop be Included in the study, or should a
representative sample be selected for analysis.
Once this decision is made, then the procedure in PFA consists of the following steps:
STEPS IN PRODUCTION FLOW ANALYSIS
1. Data collection – operation sequence and machine routing for each part
2. Sortation of process routings – parts with same sequences and routings are
arranged into “packs”
3. PFA chart – each pack is displayed on a PFA chart
Also called a part-machine incidence matrix
4. Cluster analysis – purpose is to collect packs with similar routings into groups
Each machine group = a machine cell
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.
• We cluster parts to build part families
• Cells lead to Flow Mathematics
• Cells contain all equipment needed to produce a part family
• Cells allow development of Multi-functional workers
• Cells hold work teams responsible for production and quality “They
Empower” the workers
• Empowered to set internal schedules
• Empowered to assign tasks
• Empowered to train and rotate jobs
• Etc, etc, etc

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RANK ORDER CLUSTERING

 Rank order Clustering
 This method automates the cluster study by computing Binary weights
from a machine – part matrix
 It orders parts and machine cells ‘automatically’ by structuring and
computing the matrix with binary weights
 It implies a computer algorithm for solving the clustering problem
 It may not solve if machines are needed by more than one family –
forces intelligence in application and hand scanning after several
ordering iterations.
RANK ORDER CLUSTERING METHOD
1. For each row of the machine/part matrix (M/P/M) read the pattern of cell
entries as a binary word. Rank the rows by decreasing binary value. Equal
values stay in same order.
2. Ask if newly ranked rows in the matrix are the same as previous order? – Yes
(STOP) No (continue)
3. Re-form the M/P/M with rows in new descending order. Now rank the
columns by decreasing binary word weight. Columns of equal weight are left
where they are
4. Are current column weights the same as current column order? Yes (STOP), No
(continue)
5. Re-form the matrix column order per rank order (highest to left) and return to
step-1.
RANK ORDER CLUSTERING METHOD: EXAMPLE-1 --- 5 MACHINES AND 6 PARTS

RANK ORDER CLUSTERING METHOD: EXAMPLE-1 --- 5 MACHINES AND 7 PARTS

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ISSUES IN CLUSTERING:
 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 ‘skipped’ machines in a cell
 Generally speaking, these clustering algorithms are designed to convert
existing routes for facility re-organization
 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

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