Cellular Manufacturing

and Plant Layout

Superfactory Excellence Program™

www.superfactory.com

© 2004 Superfactory™. All Rights Reserved. 1

 Outline

 Fundamentals of layout
 Process

 Product

 Fixed

 Hybrid

 Cellular Manufacturing
 Characteristics

 Implementing Cells
 Part Families
 Production Flow Analysis

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 Product Layout

Part #1 L L M D G

A A
Receiving L M G G
Part #2
L M D Shipping
Part #3

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 Empowered Employees in Cells

• Goals and tracking charts are maintained and posted.

• Problems are solved through daily cell meetings and problem
solving teams.
• The inventory management system is a KANBAN Demand Pull
instead of a work order/kit picking system.

• Cells are responsible for planning, scheduling and expediting

directly with vendors.

• They establish and maintain a KANBAN system with the

vendors.

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 Factory Flow Analysis - Methodology

• Study and map the existing flow system

• Identify the dominant material flows between shops (or
buildings)
• Determine the Process Route Number (PRN) for each part
• Analyze the part by PRN.
• Combine closely associated processes at departments that
complete most of the parts they make
• If parts are observed to backtrack then such flows are
eliminated by minor redeployment of equipment

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 Group Analysis

 The flows in each of the individual shops (identified by

FFA) are analyzed.
 Operation sequences of the parts that are being
produced in a particular shop are analyzed to identify
manufacturing cells.
 Loads are calculated for each part family to obtain the
equipment requirements for each cell

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 PFA: Weakness

 PFA is suitable mostly for small-sized applications, but it

has difficulties coping with some large cell formation
problems when the Machine-Part Matrix becomes more
complex because of problem size

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