INDUSTRIAL ENGINEERING AND MANAGEMENT

Dr.T.Sampath Kumar, Asso. Prof. VIT

1 05-11-2019
University, Vellore
 CELLULAR MANUFACTURING

Dr.T.Sampath Kumar, Asso. Prof. VIT

2 05-11-2019
University, Vellore
Today, small “focused factories” are being created as
independent operating units within large facilities

This effort is largely based on the concept of Group

Technology (GT)

It is a theory of management based on the principle

that similar things should be done similarly

Dr.T.Sampath Kumar, Asso. Prof. VIT

3 05-11-2019
University, Vellore
Cellular manufacturing

This divides the manufacturing facility into small

groups or cells of machines
Each cell is dedicated to a specified set of part
types
A cell is a small group of perhaps one or two
machines but seldom more than five

Dr.T.Sampath Kumar, Asso. Prof. VIT

4 05-11-2019
University, Vellore
A typical cell might contain a machining center, on-
machine inspection and monitoring devices, tool and
part storage, a robot for part handling, and the
associated control hardware

This is appropriate for medium-variety, medium-

volume environments

Dr.T.Sampath Kumar, Asso. Prof. VIT

5 05-11-2019
University, Vellore
It attempts to obtain the advantages of flow line
systems

Instead of large process layout with each job being

designed in a way that is independent of previous
designs, a product type layout within each group is
aimed

The resultant groups are each dedicated to a family of

parts
Dr.T.Sampath Kumar, Asso. Prof. VIT
6 05-11-2019
University, Vellore
Dr.T.Sampath Kumar, Asso. Prof. VIT
7 05-11-2019
University, Vellore
Dr.T.Sampath Kumar, Asso. Prof. VIT
8 05-11-2019
University, Vellore
Dr.T.Sampath Kumar, Asso. Prof. VIT
9 05-11-2019
University, Vellore
Whenever possible, new parts are designed to be
compatible with the processes and tooling of an
existing part family

Experience is quickly amassed on part families

Standard process plans and tooling can be developed

for this restricted part set

This quickens part changeovers, allow short cycle,

just-in-time production
Dr.T.Sampath Kumar, Asso. Prof. VIT
10 05-11-2019
University, Vellore
The design of a new part is initiated by retrieving the
design for a similar, existing part

This plan is then modified as necessary for the new

part

This is developed more quickly by relying on decisions

and documentation previously made for similar parts

This reduces document preparation time

Dr.T.Sampath Kumar, Asso. Prof. VIT
11 05-11-2019
University, Vellore
Composite part families
This simplifies the identification of groups and
also provides a basis for the design of group
tooling
Standard machine setups are possible
All members of a composite part family would
need to be of the same material and fixtured by
the same method as well as being similar in size
and requiring the same tools and machines
Dr.T.Sampath Kumar, Asso. Prof. VIT
12 05-11-2019
University, Vellore
Example

All parts in a composite part family should fit in

the same collet or chuck for turning and use the
same cutting tools, angles, fluids, and chip-
removal system

Dr.T.Sampath Kumar, Asso. Prof. VIT

13 05-11-2019
University, Vellore
Dr.T.Sampath Kumar, Asso. Prof. VIT
14 05-11-2019
University, Vellore
In functional process layout, all parts travel through
the entire shop

Scheduling and material control are complicated

Job priorities are difficult to set and large work-in-

process inventories are seen

With GT, each part type flows only through its specific
group area
Dr.T.Sampath Kumar, Asso. Prof. VIT
15 05-11-2019
University, Vellore
Workers are cross-trained on all machines within the
group

Machine scheduling is simplified

Reduced setup times allow faster adjustment to

changing conditions

Dr.T.Sampath Kumar, Asso. Prof. VIT

16 05-11-2019
University, Vellore
GT flow line
It is used when all parts assigned to the group
follow the same machine sequence and require
relatively proportional time requirements on
each machine
It operates as a mixed-product assembly line
system
Automated transfer mechanisms can be used
within the group for handling parts
Dr.T.Sampath Kumar, Asso. Prof. VIT
17 05-11-2019
University, Vellore
GT cell
It allows parts to move from any machine to any
other machine
Although flow is not unidirectional, machines
are located in close proximity

Dr.T.Sampath Kumar, Asso. Prof. VIT

18 05-11-2019
University, Vellore
GT center
It is a logical arrangement
Machines may be located as in a process layout
by using functional departments
But each machine is dedicated to producing only
certain part families
These are appropriate when large machines are
already located and cannot be moved
Dr.T.Sampath Kumar, Asso. Prof. VIT
19 05-11-2019
University, Vellore
 GT Flowline

GT Cell

GT Center
Dr.T.Sampath Kumar, Asso. Prof. VIT
20 05-11-2019
University, Vellore
Dr.T.Sampath Kumar, Asso. Prof. VIT
21 05-11-2019
University, Vellore
Three basic steps

Coding
Classification
Layout

Dr.T.Sampath Kumar, Asso. Prof. VIT

22 05-11-2019
University, Vellore
Coding
It involves the specification of knowledge
concerning the similarities between parts

It involves the assignment of a symbolic or

numerical description to parts based on their
design and manufacturing characteristics

Dr.T.Sampath Kumar, Asso. Prof. VIT

23 05-11-2019
University, Vellore
Major issues in a coding system
part (component) population
code detail
code structure
(digital) representation
Coding systems
Brisch-Birn, MULTICLASS and KK-3
OPITZ is most widely used
Dr.T.Sampath Kumar, Asso. Prof. VIT
24 05-11-2019
University, Vellore
The code should be sufficiently flexible to handle
future as well as current parts
The scope of part types to be included must be known
(rotational, prismatic, sheet metal, etc.)
The code must discriminate between parts with
different values for key attributes (material,
tolerances, dimensions, etc.)

Dr.T.Sampath Kumar, Asso. Prof. VIT

25 05-11-2019
University, Vellore
Too much coding detail results in cumbersome codes
and the waste of resources in data collection

With too few details and the code becomes useless

Features like outside shape, end shape, internal

shape, holes and dimensions are typically included in
the coding scheme

Dr.T.Sampath Kumar, Asso. Prof. VIT

26 05-11-2019
University, Vellore
Codes are generally classified as
hierarchical (monocode)
chain (polycode)
hybrid
Part coding is helpful for design and group formation
GT is a logical approach to product and facility
planning

Dr.T.Sampath Kumar, Asso. Prof. VIT

27 05-11-2019
University, Vellore
Classification
It refers to the use of part codes and other
information to assign parts to families

Parts families are assigned to groups along with

the machines required to produce the parts

To group machines, part routings must be known

Dr.T.Sampath Kumar, Asso. Prof. VIT

28 05-11-2019
University, Vellore
The basic idea is
identify items that are made with the same
processes / the same equipment
these parts are assembled into a part family
can be grouped into a cell to minimize material
handling requirements

Dr.T.Sampath Kumar, Asso. Prof. VIT

29 05-11-2019
University, Vellore
The clustering methods can be classified into
Part family grouping
Form part families and group machines into cells
Machine grouping
Form machine cells based upon similarities in
part routing and then allocate parts to cells
Machine-part grouping
Form part families and machine cells
simultaneously
Dr.T.Sampath Kumar, Asso. Prof. VIT
30 05-11-2019
University, Vellore
The most typical methods are the machine-part
grouping ones
Typically one starts with a matrix that shows which
part types require which machine types
The aim is to sort the part types and machines such
that some kind of block diagonal structure is obtained

Dr.T.Sampath Kumar, Asso. Prof. VIT

31 05-11-2019
University, Vellore
Group 1: parts {13, 2, 8, 6, 11}, machines {B, D}
Group 2: parts {5, 1, 10, 7, 4, 3}, machines {A, H, I, E}
Group 3: parts { 15, 9, 12, 14}, machines { C, G, F}
Dr.T.Sampath Kumar, Asso. Prof. VIT
32 05-11-2019
University, Vellore
How this sorting can be done?
Various heuristics and exact methods are available
Binary Ordering (Rank Order Clustering, King’s
algorithm)
Single-Pass Heuristic
LP Model
Clustering using similarity coefficients
Graph Partitioning
Metaheuristics
Dr.T.Sampath Kumar, Asso. Prof. VIT
33 05-11-2019
University, Vellore
Layout
It is concerned with the physical placement of
production facilities (machines) on the shop
floor

Within a group this becomes the choice of flow

line, center, or cell

Dr.T.Sampath Kumar, Asso. Prof. VIT

34 05-11-2019
University, Vellore