Best Performing Consulting Organization

Presents

“Cellular Layout”

Adding Value In Totality !!

 A NOTE ON ‘CELLULAR MANUFACTURING’

THE ROUTE TO COMPETITIVENESS IN MANUFACTURING

(for discreet products)
CELLUAR MANUFACUTURING
Emerged from
TRADITIONAL MANUFACTURING or ‘MASS MANUFACTURING ‘
(conceived during 1909-1915),
to
‘LEAN MANUFACTURING’
which evolved during 1970’s / 80’s

This is the secret magic that caused sudden emergence of Japan

from the ruins of the second word war to a world economic
power within a matter of 3 decades!
 The Key value Adding Processes

FABRIC issued Lay & Cut

from store

Pressing and Sewing

Packing
 This leads to application pf all
Tools…
• Line Balancing
• ALL Elements of 5S
• Basic Fundametals of IE
• All 8 types of MUDA.
• MURA
• MURI
• Trigger –Projects for QCO/AM/
RULES FOR CELL DESIGN
• Lay out machines/operations in sequence of
operations
• Machines close together
• Input to cell close to output
• Multi-operation handling by operators
• One piece flow or small bundles
• Work to ‘TAKT Time’
 Approach….
• Target demand
• Use of TAKT time,=Available
Time/Demand.
• Total Work content
• Value adding Processes
• Number of Operators.
• Stations.
 8 types of MUDA.( obstruction to FLOW)

1) Transportation –
2) Motion –
2) Waiting –
4) Over Processing –
5) Rework
6) Overproduction
7) Inventory
8) Unused creativity (Untapped Human Potential)
 Major Paradigm shifts:
• Batch Single piece
• Process layout to Product layout
• Explore new ideas,Standing operations,
• More Handoffs=More Mudas
• Organisation Structure:
• Functional Heads – value Chain Heads
• End to End responsibility.
• Multiskill at all levels:Operators to Heads.
 Application of Kaizen tools:
• Problems get exposed which needs attenntion and
solutions(basic philosophy of kaizen)
• Whether
• Machine speed,(Primary data on rated speed and Analysis)
• Changeover time(QCO)
• Frequent breakdowns(TPM)
• Material storage on Station-How,What,How Much (Work
station design).
• Raw Material supply –kanban,Milkman system
• Of Course 5 S is the foundation:Implementation of 5 S is
vital and must in a Cell.
 PQ ANALYSIS FORM
Process-Quantity Analysis
Operation
Qty.
Machine
Month
Item

* Operation Cycle Time

 PQ ANALYSIS FORM
Process-Quantity Analysis
Operation Cutting Turning Drilling Deburring
Qty.
Machine Lathe Lathe SAW CNC CNC Lathe
Month
Item 160 21 33 1 2 650
1 2 3 10 *
60 *
210 *
5000 A *150
4
5

190 * * 6
20

1500 B

* Operation Cycle Time

• Major Shift which
drives “CELL”….

Target Demand
The Batch Manufacturing Layout,
Before (schematic)
Line – 3 (~2000 Pcs per day)

Collar
Assembly

Cuff Trim/Exam
&
Front
Finishing,
Assembly
Packing
Back Sleeve
 The New Cellular System
(one cell 500 Pcs)
JIT cuff part supply
JIT collar part supply

End
Main assembly start
line
JIT
Back part
supply
JIT Sleeve part supply
JIT front part supply
 JIT Assembly
Da te : 20 / 04 / 04
Se ction : Asse mbly
Ma nning for Asse mbly

OPERATION NAME QTY PCS/HR MACHINE TYPE QTY REQ REMARKS

Join shoulder Sahu Bhagwan 80 A/utomatic m/c 1

Brother (DB2-B201-413)

Set sleeves Aimin 55 MH 380 -Juki (201613) 1

T/S + Trim armhole Pitambar 90 MH 380 - Juki(AO3822) 1

Close sides Rajesh 60 Lapseam -m/c 1

Brother ( B925 )

Trim tail/Neckhole Chantal 60 Table + iron 1

Hem tail Suresh 60 A/utomatic m/c 1

Juki D2N-541ON-7

Set cuff Baskar 40 A/utomatic m/c 2

Venkataraman 25
65

Set collar Vishwa kumar 55 A/utomatic m/c 1

Juki (DDL -555ON-3)

B/hole - front, band, Sumaty Brother (LK3 -B438E) 1

55
sleeve, cuff Poonum B/hole L852911 1
2

Marking front, B/D,slv, Anuradha Follow up

pocket

B / Sew Front, clr band Ravi B /sew 1

55
B/D ,sleeve,cuff,pocket Shalina Brother (LK3-B438E)
Juki (LK 1903 )
Table 1
2

No of operators req. : Mach :12

Pso :2
The New Cell created in Sewing Area
(difficult to capture the Cell in a 2 dimensional photo)
.
 Close Up

The main assembly line

(U shaped - face to face operators)

The cuff JIT supply cell

The point
where the „U‟ turn
 Benefits (Cellular Mfg in Sewing)
Before After % improvement

Productivity Index 2000/164/11 540/31/9 90%

(pcs/person/hr) 1.1 (for one cell)
2

T.P.T 3 days 1 day 66%

(time from trim to box)

Space for operation 1250 Sq Ft 860 Sq Ft 30%

WIP Very (about 5000 114 huge !!

Pcs) (for this cell)

Defects Normally high in Will drop with one Pcs Within finishing
batch Prod flow should be zero
Model sewing cell
Front preparation
Back preparation
Sleeve preparation
Cuff preparation
Collar preparation
Assembly
 Gemba
CUTTING FUSING
 OLD LAYOUT NEW LAYOUT

Before After % improvement

Output .042 .057 36%

Pcs/person/min 240 pcs/day 368 pcs/day
WIP 110 pcs 15 pcs.

TPT 80 min 26min

Material movement

Space occupied 30%

 READY CUTTING LAGUNA 1 CURRENT FLOW
TROLLEY Operations Flowing of GO # 4392 M&S TOP

CHECKING
BACK FRONT SLEEVE

13
TRIMMING

12
3 4 1 9 11

GARMENTS
FINISHED
TROLLEY

READY
FRONT SLEEVE
FRONT PATCH SLEEVE BOTTOM
PATCH ATTACH &
FLATLOCK 6 HEMMING HEMMING
ATTACH SIDE O/L

NECK BINDING
2 5 7 8 10
SHOULDER SLEEVE
LABEL
TAPE & KEY BARTEK ATTACH & FINISH TAKI
ATTACH HOLE O/L SIDE O/L

Benefits
READY CUTTING Targeting to Produce 400 Pcs per Day.
OPERATORS First phase of line balancing compleeted and final trials are on today.
FABRIC FLOW 30 % Space Saving.

BUNDLE Muda of Bundle Handling Eliminated.

Real Single Piece Flow Started.
The Wip on Line Will Be About 15 Pcs Only.
 PCS.
BEFORE

0
25
50
75
100
125
150
175
200

51
SLEE VE HEMMING

16
LABE L A TTACH
DATE: 23/09/2004.

PA TCH A TTACH

67
FLAT LOCK ON
129

PA TCH

SHOULDER O/L & 69

KE Y O/L

45
NE CK B INDING
56

BA RTACK

DATE
SLV O/L
69

SLV & SIDE O/L

86
AVERAGE CYCLE TEAM

72

SLV TA KI

BOTTOM
68

HE MMING

TRIMMING
90

CHECK ING
88
AVG. CYCLE TIME

takt
 Cycle time (in seconds)

0
10
20
30
40
50
60
70
80
90
100
110
120
130
140

SLEEVE HEMMING

51
LABEL ATTACH

16
37
PATCH ATTACH

67
1st level Improvement

FLAT LOCK ON

92
PATCH

SHOULDER O/L &

KEY O/L 69

NECK BINDING
45

BARTACK
56

SLV O/L
69
AVERAGE CYCLE TIME

SLV & SIDE O/L

86

SLV TAKI
72

BOTTOM HEMMING
68

TRIMMING
90

CHECKING
88
DATE : 23/09/2004
 PRODN.

0
25
50
75
100
125
150

34
LABEL ATTACH
DATE: 24/09/2004

PATCH ATTACH

56
FLAT LOCK ON PATCH

68
2 nd level Improvement

SHOULDER O/L & KEY

70
O/L

NECK BINDING 36

BARTACK
47
LAGUNA 1

SLEEVE HEMMING
62
GO#4392 M&S TOP IN
AVERAGE CYCLE TIME OF

SLV ATTACH & SIDE O/L

75

53

FINISH TAKI

BOTTOM HEMMING
62

TRIMMING
81

CHECKING
84
 UNI-CHRO ANALYSIS
GO# 4578 LA SENZA VEST

Part No. B

Part Name
FRONT BODY BACK BODY
Time requited fo r
Process Total pro cessing each
No. time part

1 32 Lace overlock 15 Main label attach

2 66 66 34 Lace top stitch

3 153 72 72 Front elastic attach & taki

4 73 Side overlock

5 70 Binding & strape cutting

6 40 Bottom hemming

7 60 Finish taki & marking

8 491 338 95 Trimming & checking

SINGLE NEEDLE TRIMMER

4 THREAD OVERLOCK

FLATLOCK

FLATLOCK CUTTER

MANUALLY
 KOHINOOR : A
OPERATION FLOWING OF GO#4578 LA SENZA VEST

1 8
LACE OVER LOCK TRIMMING
FRONT BODY
&
CHECKING

2
LACE TOP
STITCH
MARKING
&
FINISH

Round trolley
TAKI
BACK
BODY
3
FRONT
ELASTIC &
LABEL 6
ATTACH BOTTOM
HEMMING

5
4 R
O BINDING
U
N &
SIDE O/L D
T
R
STRAPE
L
O
CUTTING
L
E
Y
Y
 OLD LAYOUT NEW LAYOUT

Before After % improvement

Output 10.1(base 11.7(16%)

Pcs/person/hour data)

WIP 40 9
TPT To be Target to be set
measured
Material Movement 6 mtrs 2 mtrs

Space Occupied 28 sq.Mtrs 16 Sq.mtrs

 STANDARD OPERATION CHART
MILLENIUM - 2
Station -1 R
o
Pressing d
Station - 3 STD : C/WS/FIN/PR/01
Packing
STD :
C/WS/FIN/PK/01

Station -2
Pressing R
o
STD : C/WS/FIN/PR/01 d
 Station -1 R
o
Pressing d
Station - 3 STD : C/WS/FIN/PR/01
Packing
STD :
C/WS/FIN/PK/01

Station -2
Pressing R
o
STD : C/WS/FIN/PR/01 d
 New layout (PACKING)

By 30th June

Cell 5 Cell 4 Cell 3 Cell 2 Cell 1

19th March
May 14th

From
pressing
 New Ironing Cell
16 feet

12 feet
Opening s-seam Plain to bottom

From sewing To packing

Back Plain Pocket bag

New door to packing room

New Cell Created in Pressing
Shop…

Through put time :4

minutes.
Old Layout (Finishing Area)
Trim &
flow Exam

Pressing

Button

Folding

Poly Bag

FG Trolley
 Design of New Finishing Cell‟s
Wash Gar Cell
in
1 2 3 4

Packed Garment
out
4 Finishing Cell = 1800 Pcs / 36 people / in 9 hrs (still improving)
Layout Before – 130 Sq Mtrs.

Linking WIP trolleys Stitching/Light Inspection

 Cellular Layout After – 30 Sq meters

100 Sq meters freed

Linking WIP trolleys Stitching/Light Inspection

 The New Cell Created in Finishing Area.

Starts with
Trim & Exam

Press

Button

Folding

Poly bag
and direct to box
The New Cell created in Finishing Area.
 Benefits (Cellular Mfg in Packing)
Before After %
improvement
Productivity Index 2072 pcs / 43 1800 pcs / 36 20%
(pcs/person/day) operators / 10.75 operators / 9 hours
hours = 4.5 = 5.6
T.P.T 9 hrs 12 mins 97 %
(time from trim to
box)
Space for operation 5760 Sq ft 1440 70%
WIP 500 15 97%
Defects Normally high Will drop with one Within finishing
in batch Prod Pcs flow should be zero
Total Activity of Measure width,Match
shade,group,put in trolley is MUDA…which we
may have to stay with for sometime..
One roll
flow,Direct 9 transfers reduced to 3
to
TROLLEY..

MUDA
eliminated…. cut
fabric and waste
75mm width of
fabric per roll.
 EXAMPLE OF
STANDARD OPERATIONS FORM
STANDARD
OPERATIONS
CHART

CELL NAME :

A02 A01
PROCESS NAME :

AO3
3 2 1 Raw
DESCRIPTION OF OPERATION :
Materials
\
PREVIOUS NEXT 4
PROCESS: PROCESS:
5 6 7 Finished
goods
CYCLE TIME: TACT TIME :
A04 B01

AMT.OF FREQUENCY:
STANDARD WIP

Stand.in Quality Safety

- check check
process point point
inventor
y
DATE : PREPARED BY:
Revision date Revision
STANDARD
LINE NAME OPERATIONS
: FORM

PROCESS NAME :

DESCRIPTION OF OPERATION :

\
PREVIOUS NEXT
PROCESS: PROCESS:

CYCLE TIME: TACT TIME

:

AMT.OF FREQUENCY.
STANDARD WIP :

Stand.in Quality Safety

-process check point check
inventory point

DATE : PREPARED BY:

Revision date Revision
 STANDARD OPERATIONS CHART

Stamping
SP-101 MM-122 HP-657 BR-410 Serial Store for
1/10 Number Incoming
Cleaning
1/1 Material

7 6 5 4 3 2 1

8 9 10 11 12 13

1/50 Store for

DR-1544 1/1 CE-239 Finished
LA-1011 LA-1307 LA-1306
Products

Quality Safety Standard Quantity of Takt Net operating

Frequency
check caution Stock on hand Stock on hand Time time

12 pieces 1’53” 1/3 1’54”

Process Capacity Table
Standard Work Combination Sheet
 Cell in operation

Operators work in
close loop, thus helping
in feedback & team work
Co-Location in Offices or License
Processing …
 Before Kaizen After Kaizen

File Movement for Primary School Registration File Movement for Primary School Registration
(Before Kaizen) as on 29th June.2005 (Before Kaizen) as on 29th June.2005

3 8thFloor 8thFloor

9 10 7th 7th

6th 6th

4
5th 7 5th
16
16 16 4 3
13
13 13 2
2 12
15 11 14 10 2

4th 4th
8 7 6 5 6 5

15 14
3rd 3rd

2nd 2nd
11 8 9
12

1st 1st

GF GF
1 1
 Process Mapping-job applications. Present
4th 38 2

41 35 3rd 37

31 32 34 2nd

1st 36
33 20 19 18
42 6 5 3 25 1
10 Gr
21 12 8 13 22
7 17 24

4
26 15 11 B 9 14 23 39
40 16
43 27 28 29 30 44
End
Improved TPT For Applications Processing as of 24th June, 2005.

4th 14

11 3rd 13

10 2nd

6 1st 12

Gr 1

9 8 7 5B 4 3 2 15
Voucher
processing
room
Cells at Registration Reduced TPT

Receipt,Search,Registry,Typist,Authority,Stamping,
Issue(Dedicated Team for Birth Cert.)
 How are our people in HR Placed?
This will affect the information flow,and Customer Service.

SAD HRD 1 SAD HRD 2 SAD HRD 3

Section 1 Section 3 section 4 Section 2 Section 5

AD/HRD

PHRDO

CHRDO

SHRDO
 Spaghetti at Registration of Persons.
Before Kaizen After Kaizen

OUT OUT

IN IN

Distance Travelled by wananchi:141 Mtrs

71 Mtrs.
 ADDVALUE Services

VALUE ADDED COACHING-VAC®

BUSINESS COACHING LIFE COACHING

Operation
Counselling
Excellence

Team
Therapy
Excellence
Adding Value In Totality !!
Business
Astrology
Excellence
 AddValue at a glance
Best Performing Consulting Organization

Business Coaching Life Coaching

Thank You