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GROUP TECHNOLOGY –
[Chapter 5 of Bedworth]
Introduction of GT
Development of Part Families
Coding and Classification-basis for GT
» coding schemes
» examples of coding systems
Cellular Manufacturing
Economic Considerations - production
planning, tool analysis.
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Definition of GT
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Product Variety vs Production Quantity
Har
d MH automated
Changeover (set up)Time
Job Shop
Product Variety
Mid Variety
Mid Production
(Most Difficult)
Mass Production
Sof
t 100 10,000 1M
Low Production Quantity Hig
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Types of Production Plant (facilities) and Layout
• Fixed Position
Har (Large)
• Process • Process (Batch)
d
• Cellular (GT families)
• FMS (GT families- automated
Job Shop MH)
Product Variety
l i t y
bi
Mid Variety • Product (Flow line)
i x
Ef l e
fic Production
F
Mid • Process (Quantity)
i en
(Apply
cy GT)
Mass Production
Sof
t
100 10,000 1M
Low Production Quantity Hig
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Process Layout – typical of most
job shops
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GT layout
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WIP Distribution – Machined
Part Fabrication
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Characteristics of Job Shops -
(operations scheduling)
low-volume production, lot sizes small
machining centers organized by
manufacturing function
high labor content in product costs
general-purpose machinery
significant changeover time
little automation of material handling
large variety of products
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Need for GT
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Manufacturing Attributes
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Design and Manufacturing Attributes
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Grouping Methods –
[ Bedworth Figs. 5.3 and 5.4]
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Methods for Developing Part
Families
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Part Families Development
contd.
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Part Families Dev’t - Fig 5.5
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Part Families Dev’t contd.
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Classification and Coding
contd.
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Hierarchical Code
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Attribute Code
Characters are independent of others
in the code
each part attribute is assigned a specific
position in the code
preferred by manufacturing - easy to
identify parts that require similar
processes
disadvantage - code could be very long.
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Example - Attribute Code
(fig. 5.7)
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Hybrid Code
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Selecting a Coding System -
Factors to Consider
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Selecting Coding System
contd.
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DCLASS Coding System
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DCLASS Code - fig. 5.8
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DCLASS - fig. 5.14
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DCLASS - fig. 5.15
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DCLASS - fig. 5.16
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DCLASS - Tables 5.3, 5.4, and
5.5
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Coding Systems contd.
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MICLASS contd. - fig. 5.17
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MICLASS contd.
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Clustering Techniques: Single-
Linkage Clustering Algorithm (SLCA)
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SLCA - Similarity Coeff.
Sij = a/(a+b+c)
» where,
» s = similarity coefficient between mach i
and j
» a = # of parts common to both machines
» b = # of parts that visit only machine i
» c = # of parts that visit only machine j
Determine similarity coefficient between
machines A and D - fig. 5.21.
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SLCA contd. (fig. 5.21)
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SLCA Steps
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SLCA contd.
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Fig 5.23 and Table 5.6
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SLCA dendrogram
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Advantages/Disadvantages
of SLCA
An Advantage of SLCA is that it provides a
powerful systematic way of grouping
machines for GT mfg.
Disadvantages:
» no clear direction on how to achieve ideal
machine-groups. To decide, one need info. on a)
no. of inter-group/intra-group movements b)
machine utilization c) planning and control and d)
bottleneck machines.
» Chaining can occur – page 209 of Bedworth.
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Enhancements to SLCA
Anderberg’s Algorithm:
» Sij = 2a/(2a + b + c)
» this gives more weight to similar machines
and thus limits or controls Chaining.
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Average - Linkage Clustering
Algorithm (ALCA)
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ALCA Steps
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ALCA - fig. 5.25
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Facility Design with GT
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GT and Mfg Cells
used to show logical implementation
steps for GT
benefits include:
» reduction in number of perishable tools
» lower setup times
» lower tooling costs - tools can be “kited”
» improvement in efficiency of new
equipment.
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Economic Modeling of GT
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Tooling Costs fig. 5.28
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Typical Savings Realized from
Successful GT program-p. 221
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Types of Layout - fig. 5.20
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