Cellular Manufacturing and Plant Layout Lean Manufacturing Series

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Outline Fundamentals of layout Cellular Manufacturing Process Product Fixed Hybrid Cellular Manufacturing Characteristics Implementing Cells Part Families Production Flow Analysis

Product Layout Part #1 L L M D G A A Receiving L M G Part #2 L M D Shipping Part #3

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. The decision is stated in terms of a goal which directs the search for solutions in positive ways. A confused and unfocused group starts getting organized by concentrating on the goal of the solution, not on the solution itself. In the planning process, the goal is a given, but that is not always the case. Too often we believe the decision statement is a given. In fact, the reason for our decision is essential to opening the search for a good solution. Goals direct the search for positive ways. Ostensibly expand our goal; then create a hierarchy of goals or decision statements. Compose the decision statement using an action verb, an object and an adjective. The action verb should be prescriptive and concerned with the total set of conditions (for example, to select, choose, determine, have, establish, provide) as opposed to verbs that indicate a measurement of change or incremental goals (to increase, reduce, minimize). The adjectives modify or constrain. They reduce the range of possible solutions with a limitation.

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

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

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