chapter 15 chapter 15

Technology Group Technology and Cellular Cellular Manufacturing Manufacturing and

CHAPTER CHAPTER CONTENTS CONTENTS 15.1 rt Families 15.1 Pe Part

15.2 Parts and Coding 15.2 Parts Classification Classification and Coding 15.2.1 Features Systems Features of Parts Parts Classification Classification and and Coding Coding Systems 15.2.2 of Parts Classification and Coding Systems 15.2.2 Examples Examples of Parts Classification and Coding Systems Production Flow Analysis 15.3 Production Analysis
15.4 Cellular Cellular Manufacturing 15.4 Manufacturing 15.4.1 Part Concept Concept 15.4.1 Composite Composite Part 15.4.2 Machine Machine Cell Design 15.4.2 Cell Design 15.5 Application Application Considerations in Group Group Technology Technology 15.5 Considerations in 15.5.1 Applications Applications of Group Group Technology Technology 15.5,1 15.5.2 Survey Survey of Industry Industry Practice 15.5.2 of Practice 15.6 Quantitative Analysis in Cellular Cellular Manufacturing 15.6 Quantitative Analysis in Manufacturing 15.6.1 Grouping Grouping Parts and and Machines Machines by Rank Order Order Clustering 15.6.1 Parts by Rank Clustering 15.6.2 Machines in a GT Ceil 15.6.2 Arranging Arranging Machines in GT Cell

Batch manufactur manufacturing to be be the the most most common common form form of of production in the Unittunng Batch ing is estimated estimated to production in the United States, States, constituting constituting more more than than 50% of total manufacturing manufacturing activity. There There is a growing growing ed of total lanufacturing activity. ition, i, there thei need (o to make hatch manufacturing manufacturing more more eff efficient productive. In In additii addition, there is an an need make batch icient it and and productive. produi : increasing trend toward achieving achieving a higher higher level level1 of integration between between the design and increasing trend toward of integration integral the design and manufacturing functions in a firm. firm. An An approach approach directed directed at at both both of objectives is mfacturing functions of these these objectives group (GT). group technology technology (GT). Group technology manufacturing philosophy similar parts identified Group technology is a manufacturing philosophy in which which similar parts are are identi fied and grouped grouped together together to take take advantage advantage of of their similarities in design design and and production production. SimSimand their similarities
.

Introduction

421 42'

ilar parls parts are into pari part/amities. where each part family possesses similar similar design design ilar are arranged arranged into families, where each part family possesses and/or manufacturing manufacturing characteristics. for plant producing producing 10,000 different different part or example, example, a plant part and'or characteristics, t'

numbers may may he be able able to 10 group group the vast majority majority of of these these parts into 30-40 30-40 distinct distinct families. families numbers the vast parts into It is reasonable processing ot member of given tamny family is lable to to believe believe that that the the processing processing of each each member member of a a given given family is similar. similar. the each ot and this this should should result efficiencies. The efficiencies efficiencies are are generally generally achieved achieved and result in manufacturing manufacturing efficiencies.The hy arranging arranging the into machine groups, or facilitate work work by the production production equipment equipment into machine groups, or cells, cells, to facilitate flow. Grouping Grouping the equipment into into machine machine cells, where where each each cell specializes specializes in How. the production production equipment the production of a part part family. called cellular cellular manufacturing. manufacturing. Cellular manufacturing the production of family, is called Cellular manufacturing an example example of of mixed mixed model model production production (Section The origins group technolotechnolois an (Section 13.2.4). The origins of of group and cellular cellular production can be be traced traced to around 1925 (Historical (Historical Note Note 15.1). 15.!) gy and production can to around Historical Note Note 15.1 Historical 15.1 Grouptechnology Group technology

In ll)25. 1925.R R Flanders presented a paper in the United States before the American Society of MeIn

|
j

chanical Engineers in which he desenbed a way of organizing manufacturing at Jones and Lamson Machine Company Company that that would today today be called group group technology. technology. In 1937, 1937. A. Lamson Sokclovskiy of the Soviet Union described the the essential features by proposSokolovskiy features of group technology by iJlglhalparl,()f,imilarc()nfiglirali<Jnb"pr",Jl1c~dbyastao.dardprocess sequence, thus pering lhaL parls of similar eon fig Lira I kin tie pruduced by a standard process sequence, milling flow line techniques techniques to be used for work normally normally accomplished accomplished by batch production. mitting production. In 1949.A. paper (in Paris. France) France) on "group production." 1949. A Koding Korling of Sweden presented presented a paper "group production." adaptation of production production line techniques batch manufacturing. manufacturingInIn whose principles are an adaptation techniques to batch paper. he describes decentralized into independent independent groups grcups, each of which conthe paper, describes how work is decentralized tainst~_emaehillcsandlO{}ling\Qproduce"aspecialcategoryofparts." tains the machines and tooling to produce "a special category of parts." lnl959,researcherS.MilrofanuvoftheSovietUnionpublishedabook entitled SctenSctenIn 1959, researcher S. Milrofanuv of the Soviet Union published a book entitled tiftc Principles of of Group Group Technology. Ttchnology. The Thc book book was widely considered rcsponsircspcnsitif lc Principles widclv read and is considered ble for nver 800 plants in the Soviet Union using group technology by 1%5. Another researcher, b1eforoverROOplantsinthcSovietUnionusillggrouptechnologybyJ965.Anotherresearchcr, H. Opitz in Germany Gcrrnanv studied studied workparts work parts manufactured manufactured by by the the German machine tool tool industry industry H. Opitz in German machine developed the well-known well-known parts parts classification classification and coding system machined parts parts that that and developed system for machined bears his name (Section (Section 15.2.2). 15.2.2). bears In (he the United United States, the first application appucatton of group group technology technology was at the Langston Langston DiDr around 1969. 1969.Traditionally machine shop arra arranged vision of Harris-Intertype Harris-lntertype in New Jersey around Traditionally a machine as a process type layout, company reorganized reorganized into "family "family of parts" which layout the company parts" lines, each of \ producing a given part part configuration. configuration. Part families were identified taking phospecialized III in producing identified by taking 1;;: of the made in the plant plant and grouping implctos of about 15 157r parts made grouping them into families. When implemerueu.me cnanges improved producnvtty by 50%and eeks to days. days mented, (he changes improved productivity 50% and reduced reduced lead times from weeks
,

Group technology and cellular manufacturing manufacturing are applicable applicable in a wide wide variety variety of of Group technology and cellular are manufacturing situations. situations. GT GT is most most appropriately appropriately applied applied under under the following following conditions: manufacturing conditions: The The plant plant currently currently uses uses traditional production and and a process process type type layout layout . traditional batch batch production (Section this results results in much much material material handling handling effort, effort, high high in-process in-process in(Section 1.1.2), and and this ventory, manufacturing lead lead times. times . ventory lind and long long manufacturing
,

. The parts The part families. This necessary condition. condition, Each Each mamaparts can can be be grouped grouped Into Into pan families.T his is a necessary

chine produce a given or limited collection of of part part famfamchine cell is designed designed to produce given part part family, family or limited collection ilies, so it must to group group parts parts made made in the the plant plant into into families. However, must be possible possible to families However, would be unusual to to find mid-volume production production plant plant in which which parts parts could could not not it would be unusual find a mid-volume he grouped grouperl into into part families be part families
,
.
.

There are two two major major tasks tasks that that a a company company must must undertake undertake when when it it implements implements group There are group technology. These two two tasks tasks represent significant obstacles obstacles to the technology. These represent significant the application application of of GT. GT
.

422 422
I 1
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Chap. 15 15 / I Group Technology and Cellular Cellular Manufacturing Chap. Group Technology and Manufacturing

Identifying the part part families, families. if If the the plant plant makes makes 10,000 10,000 different parts, reviewing reviewing all Identi fying the different parts, of the the part part drawings drawings and and grouping grouping the parts into into families substantial task task that that of the parts families is a substantial consumes a significant significant amount amount of of time. time. consumes

2 2. Rearranging machines into machine cells. time consuming consuming and and costRearranging production production machines into machine cells. It is time cost.

ly lo 10 plan plan and and accomplish accomplish this this rearrangement, rearrangement, and the machines machines are are not not producing producing ly and the

during the changeover during the changeover. Group technology technology offers substantial benefits companies that that have the perseverance Group offers substantial benefits to companies have the perseverance to implement it. The benefits benefits include: include: to implement it.The GT GT promotes promotes standardization standardization tooling, fixiuring, fixturing. and and setups. setups. . of tooling
,

reduced because because parts parts are are moved moved within within a machine cell rather rather . Material Material handling handling is reduced machine cell than factory. than within within the the entire entire factory. production scheduling scheduling are are simplified. simplified . Process Process planning planning and and production . Setup Setup times times are are reduced, reduced resulting resulting in lower lower manufacturing manufacturing lead times. lead times.
,

reduced. . Work-in-process Work-in-process is reduced . Worker Worker satisfaction satisfaction usuall usuallyy improves improves when when workers workers collaborate collaborate in a GT OT cell.
.

accomplished using using group group technology technology. . Higher Higher quality quality work work is accomplished
,

In this discuss group group technology, technology, cellular manufacturing, and and several several related this chapter, chapter we discuss cellular manufacturing, related topics. defining an underlying underlying concept group technology: technology: part part families. topics. Let Let us begin begin by defining concept of of group families.

15.1

PARTFAMILIBS PART FAMILIES

Apart of parts parts that that are similar either either because because of of geometric shape and and A part family family is a collection collection of are similar geometric shape size processing steps steps are are required their manufacture. The parts parts withwithsize or or because because similar similar processing required in their manufacture.The family are are different, different but in a family but their their similarities similarities are are close enough to mer merit their inclusion i.nclusion as close enough it their members Figures 15.1 and 15.2 show show two two different different part part families. families. The The two two members of of the the part part family. family. Figures 15.1 and parts very similar similar in terms terms of of geometric geometric design, design, but but quite quite different different in parts in Figure Figure 15.1 15.1 are are very terms because of of differences differences in tolerances tolerances, production quantities, and and terms of manufacturing manufacturing because production quantities, material. shown in Figure Figure 15.2 constiiute constitute fl. part family f<lmily in manufacturing, but material. The The ten ten parts parts shown a part mamifacturing but their make them appear quite from a design their different different geometries geometries make them appear quite different different from design viewpoint. viewpoint. One manufacturing advantages of of grouping grouping workparts workparts into into famifamiOne of of the the important important manufacturing advantages lies reference to Figures Figures 15 15.3 and 15.4. Figure Figure 15.3 shows shows a process lies can can be be explained explained with with reference 3 and process
,

Figure Two parts parts of of identical identical shape and size size but but different different manmanFigure 15.1 Two shape and ufactuiing requirements: requirements: (a) ufacturing (a) 1 1.000,OOOpc/yr, tolerance = O.OlOin, 000,000 pc/yr, tolerance = 0.010 in, material = = 1015 material 1015 CR CR steel steel, nickel nickel plate; plate; and tolerand (b) (b) 100 pc/yr, pc/yr, tolerance = = D.DO! 0.001 in =18-8 stainless steel. steel. ance in, materia] material = 18 - 8 stainless
.

Sec. Part Families Sec. 15-1 15.1 / I Part Families

423 423

Figure family of of parts parts with similar manufacturing process Figure 15.2 A family with similar manufacturing process requirements but different design altributes. attributes. All All parts parts are are machined requirements but different design machined from cylindrical stock stock by by turning; turning; some parts require and/or from cylindrical some parts require drilling drilling and/or nulling. milling.

Turn

Turn

Mill

Mill

Mill

Urll

Urll

Man

Man

Man

Turn

Mill Man

Mill

Mill

Drll

Drll

Man

Turn

rum

Mill

Man

Gmd

Gmd

Shipping and rece,vl1lg

Gmd
Mai Man

Figure 15.3 Process Process type type plant plant layout. layout. (Key: (Key: "Thm" turning, Figure '"Rim" = turning
" " ,
" " ,

"Mill" = milling,"Drll" milling,"Drll" = d drilling,"Gmd" grinding,"Asby" asMill" = rll" = rilling lling," Gmd" Gmc = - gr inding, "Asby" = = a an sembly, "M "Man" == manual operation; operation; arrows indicate work work flow flow sembly = manual open arrows indicate through plant, plant, dashed dashed lines lines indicate separation of of machines machines into into through indicate separation departrnerrts.} departments.)

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Chap. Chap. 15 15

I / Group Group Technology Technology and and Cellular Cellular ManufacturIng Manufacturing

Mill

Drll

Man

Man

Mar

r"
, '
"'

J Mill
Man

Dtll

Grad
Man

*1 Man

Mill

Urll

3nid
Man

Man

Figure 15.4 Figure 15.4 Group Group technology technology layout. layout. (Key: (Key: "Turn" "Turn" = = turning, turning, "Mill" = milling,"Drll" = drillingrGmd" = as-Mill" = milling, "Drll" = drilling, "Gmd" = = grindmg.-Asby'' grinding "Asby" = assembly, Man" = = manual manual operation; operation; arrows arrows indicate indicate work work flow flow in rnamasembly,"Man" chine cella} chine cells.)
"

"

type plant layout layout for for batch production in a machine shop. The tools are type plant batch production machine Sihop. The various various machine machine tools are arranged arranged by function. function. There There is a lathe lalhe department, department, milling milling machine machine department, department, drill drill press press department, department, and and so so all. on. To machine machine a given given part, part, the the workpiece workpiece must must be be transporttransported between departments, with perhaps the same department being visited several times. ed between departments, with perhaps the same department being visited several times. This material handling, This results results in a significant significant amount amount of material handling, large large in-process in-process inventory, inventory, many many machine setups, machine setups, manufacturing lead p ups, long long manufacturing manutactunng lead times, times, and and high high cost. cost. Figure Figure 15.4 15.4 shows shows a proproduction but duction shop shop of of equivalent equivalent capacity, caf capacity, but the the machines machines are are arranged arranged into into cells. cells. Each Each cell cell to specialize specialize production of a particular Advantages of rereo is organizt;:d organised to Hze in thc thi production the particular part part family. Advantages duced iced workpiece workpiece handling handling yield yield lower lo\ duced lower setup setup times, limes, fewer fewer setups setups (in (in some some cases, cases, no no setup setup changes are necessary), changes are necessary), less less in-process in-process inventory, tnvenlory, and and shorter shorter lead lead times. times. The biggest The biggest single single obstacle obstacle in changing changing over over to to group group technology technology from from a convenconventional tional production production shop shop is the the problem problem of of grouping grouping the the parts parts into into families. families. There There are are three three general for solving general methods methods for solving this this problem. problem. All All three three are are time time consuming consuming and and involve involve the the analysis analysis of of much much data data by by properly properly trained trained personnel. personnel. The The three three methods methods are; are: (1) (1) visual visual ininspection, and (3) production spection, (2) parts parts classification classification and and COding, coding, and production flow flow analysis. analysis. Let Let us proprovide vide a brief brief description description of of the the visual visual inspection inspection method method and and then then examine examine the the second second and and third methods in more detail. third methods in more detail. The visual inspection The visual inspection method method is the the least least sophisticated sophisticated and and least least expensive expensive method. method. >sificat It of iy looking looking at at either ( It involves involves the the classification classification of parts parts into into families families by either the the physical physical parts parts or or their photographs and their photographs and arranging arranging them them into into groups groupss having features Although having ing similar simil features. similar features. Although this this method generally considered method is considered to to be be the the least least accurate accurate of of the the three. three one s generally one of the the first first majormajor :ories of success stories the changeover of GT GT in in the the United United States States made made the changeover using using the the visual visual inspection inspeciion
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Sec. Parts Classification Sec. 15.2 / Parts Classification and and Coding Coding

425

method. This This was Langston Division Division of Harris Inlertype Intertype in Cherry Cherry Hill, Hill, New New Jersey Jersey method. was the the Langston of Harris [18] [HistoricalNote [18] (Historical Note rs.u 15.1).

75.2 15.2

PARTS PARTS CLASSIFICATION CLASSIFICATION AND AND CODING CODING

lhis is the most most time time consuming consuming of of the the three three methods. parts classification classification and and coding, coding, This methods. In Inports similarities among among parts are identified, identified, and and these these similarities similarities are are related related in a coding system. similarities parts are coding systiTwo categories categories of of part part similarities similarities can can be be distinguished: distinguished: (1) (1) design which arc Two design attributes, attributes, which are concerned with pan part characteristics characteristics such such as geometry geometry, size, size, and and material; and (2) (2) manufacmanufae-material; and concerned with turing attributes, attributes, which which consider consider the the sequence sequence of of processing processing steps steps required part. turing required to make make a part.
,

While the design design and manufacturing attributes attributes of of a part part are usually correlated, correlated, the the correWhile and manufacturing are usually corretauon is less than perfect. Accordingly, classification classification and and coding are devised devised to inlation less than perfect. Accordingly coding systems systems are clude both part's s design design attributes attributes and its manufacturing attributes. Reasons Reasons for using a clude both a part and its manufacturing attributes. for using coding scheme scheme include; include: coding
,
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Design Design retrieval retrieval. A A designer designer faced faced with with !he the task task of developing developing a new part can can use use . new part
.

a design design retrieval retrieval system system to to determine determine if a similar similar part part already already exists. exists. A simple A simple change in an existing existing part part would would take take much much less time than than designing whole new new change less time designing a whole part fr from scratch. part om scratch. Automated Automated process process planning planning. The The part part code code for new part part can be used to search search for for . for a new can be used to
.

process plans plans for for existing existing parts parts with with identical identical or or similar similar codes process codes. Machine Machine cell cell design design. The The part part codes codes can can be be used used to design design machine machine cells cells capable of . capable of producing of a particular particular part part family, family, using using the the composite concept producing all members members of composite part part concept
.

(Section 15.4.1). (Section 15.4.1).

accomplish parts parts classification classification and and coding coding requires requires examination examination and and analysis analysis of the the To accomplish
examination is sometimes design and/or and/or manufacturing manufacturing attributes attributes of each part part. The The examination sometimes done done design of each looking in tables tables to to match match the the subject subject part the features features described described and and diadiaby looking part against against the
.

grammed in Ihe the tables. tables. An An alte alternative and mure-pruiiuclive more-productive approach approach involves involves interaction interaction grammed rnative and with a computerized computerized classification classification and and coding coding system, which the the user user responds queswith system in which responds to to questions asked asked by the On the the basis basis of of the the responses responses, the the computer computer assigns assigns the the code tions the computer. computer. On code
, ,

classification results results in a code number to the the part. Whichever method method is used used, the the classification code number number number part. Whichever
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that uniquely uniquely identifies the part's part's attributes. attributes. that identifies the The classification classification and and coding coding procedure procedure may be carried carried out out on on the the entire of acThe may be entire list of active parts parts produced produced by by the the ffinn, or some sort of sampling procedure may be used to to establish establish tive irm or some sort of sampling proceduremay be used
,

part families families. For For example, example, parts produced in the certain time time period period could could part parts produced the shop shop during during a certain

be examined examined to to identify identify part part family family categories categories. The The trouble with any any sampling trouble with sampling procedure procedure
.

is the the risk risk that that the the sample sample may be unrepresentative unrepresentative of the the population population. may be of number of classification classification and and coding coding systems systems are are described described in the the literature literature [13] [13], [16], A number and there there are are a number number of commercially commercially available packages. However, none [31], and available coding coding packages. However none that a classificlassifiof the the systems systems has has been been universally universally adopted adopted. One One of of the the reasons reasons for for this this is that of cation and and coding coding system system should should be be customized customized for for a it given given company company or or industry industry. A A systi system cation that is best best for one one company company may not be best best for another company company. that may not for another
.

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Chap. f Group Technology and Chap. 1S 15 / GroupTechnology and Cellular Cellular Manufacturing MamifBcturing

15.2.1 15.2.1

Features of of Parts Parts Classification Classification and Coding Systems Systems Features and Coding

The The principal principal functional functional areas areas that that utilize utilize a a parts parts classification classification and and coding coding system system are are design design three categorie,; categories; and parts classification and manufacturing. manufacturing. Accordingly. Accordingly.parts classification systems systems fall fall into into one one of of three
1 systems 1. systems based based on on part part design attributes attributes 2 systems 2. systems based based on on part part manufacturing manufacturing attributes attributes 3 systems 3. systems based based on on both both design design ond and manufocturing manufacturing attributes attributes
.

Table manufacturing attributes Table 15.1 15.1 presents presents a list list of of the the common common design design and and manufacturing attributes typically typically included classification schemes. cluded in classification schemes. A A certain certain amount amount of of overlap overlap exists exists between between design design and and manufacturing geometry is largely largely determined determined by the the sequence sequence of of manufacturing attributes, attributes, since since a part's part s geometry manufacturing manufacturing processes processes performed performed on on it. In terms the code, terms of of the the meaning meaning of of the the symbols symbols in the code, there there are are three three structures structures used usied in classification and coding schemes: classification and coding scheme
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1 hierarchicalstructure, 1. monaeode, in which hierarchical structure, also also known known as a ntonocode, which the the interpretation interpretation of each each successive successive symbol symbol depends depends on on the the value value of of the the preceding preceding symbols symbols 7 dO;'I.type 2. polyoode, in which chain-type structUN!, structure, also also known known as a polycode, which the the interpretation interpretation of of each each symbol the same; symbol in the the sequence sequence is always always the same; it does does not not depend depend on on the the value value of of prepreceding ceding symbols symbols
.
.

3 mixed-mode 3. structure. which hybrid of the two mixed-mode structure, which is a hybrid of the two previous previous codes codes
.

To distinguish distinguish the the hierarchical hierarchical and and chain-type chain-type structures, structures, consider consider a two-digit two-digit code code numn ber for a part, the general ber for part, such such as as 15 or or 25. Suppose Suppose the the first first digit digit stands stands for for the general shape shape of of the the part: 1 means geometry is rectangular. part: 1 means the the part part is cylindrical cylindrical (rotational), (rotational), and and 2 means means the the geometry rectangular. In a hierarchical second digit depends on hierarchical structure, structure, the the interpretation interpretation of of the the second digit depends on the the value value of of the If preceded the 5 might the first first digit. digit.If preceded by by 1, l.the might indicate indicate a length-to-diameter length-to-dtameter ratio; ratio; and and if prepreceded the 5 indicates ceded by 2, Ihe indicates an aspect aspect ratio ratio between between the the length length and and width width dimensions dimensions of of the the part. would have part. In the the chain-type chain-type structure, structure, the (he symbol symbol 5 would have the the same same meaning meaning whether whether prepreceded ceded by 1 1 or or 2. For For example, example, it might might indicate indicate the the overall overall length length of of the the part. part. The The advanadvantage tage of of the the hierarchical hierarchical structure structure is that that in in general. general, more more information information can can he included included in in a
TABLE TABLE

15.1

Design Design and and Manufacturing Manufacturing Attributes Attributes Typically Typically Included Included in a Group Group Technology Technology Classification Classification and and Coding System System Part Part Manufacturing Manufacturing Attributes Attributes Majorprocasses Major processes Minor operations operations Minor Operation sequence sequer Oparation Major Major dimension dimension Surface fi nish Surface finish Machine too! tool Machine Productioi Production m cycle cycle time time Batch size size Batch Annual production production Annual Fixtures Fixtures required required requirf Cutting Cutting tools tools

Part Pan Design Design Attributes Attributes Basic Basic external external shape shape Basic internal shape Basic internal shape Rotational Rotational or or rectangular rectangular shape shape Langth-to-diameter Length-to-diameter ratio ratio (rotational (rotational parts) parts) Aspect Aspect ratio ratio (rectangularpartsl (rectangular parts) Material Material type type Part function Part function Major dimensions dimensions Major Minor Minor dimensions dimensions Tolerances Tolerances ranees Surfj Surface Face finish finish

Sec. 15.2 I / Parts Parts Classification Classification and and Coding Coding Sec.

427 427

code of a given number of tligiis.The mixed-mode classification and coding system

the most common structure mon s combination o! hierarchical and chain-type structures. It is the most com
"
"

found in GT pans classification and coding systems.

The number of digits code can can range range from Coding schemes schemes that that conconThe number digits in the the code from 6 to 30. Coding tain only only design design data data require require fewer fewer digits, digits. perhaps perhaps 12 or or fewer. fewer. Most Most modem modem classification lain classification ;lntl i-nHin}i cntlin!!- -.yMems ~)'~If'm"include include hnth rlecign and and manufacturing data, and and this this usually usually requires and both design manufacturing data, requires 20-30 digits, digits. this This might might seem seem like too too many many digils digits tor fur a human human reader reader to easily easily comprehend, comprehend, 20-30 but it must must be remembered that most most of of the the data data processing processing of of the codes is accomplished accomplished but remembered that the codes computer. for for which large number number of of digits digits is of mil minor concern by computer, which a large 15.2.2 Examples Classification and Coding Systems Examples of of Parts Classification Coding Systems

Some the important (with emphasis emphasis on on those those in the the United United States) include: {he Some of of the important systems systems (with States) include: (he Opitz classification classification system, system, which which is nonproprietary; nonproprietary; the the Brisch Brisch System Sy,tem (Brtsoh-Birn, Inc.); Opitz (Brisch-Bimjnc); CODE (Manufacturing Data Systems. Systems. Inc.); lnc.]: CUTPLAN CUTPLAN (Mctcut (Metcut Associates); Associates); DCLASS DCLASS CODE (Manufacluring Data (Brigham Young Young University): MultiClass (OIR: (OIR: Organization Organization for for Industrial (Brigham University); MulliClass Industrial Research);and Research};and Part Analog Analog System System (Lovelace. (Lovelace. Lawrence Lawrence & Co., Co., Inc.). Reviews of of these these systems systems and and othothPart Inc.). Reviews ers and |23J. [23J. ers can can be found found in [161 [ I6| and In the discuss two two classification classification and and coding coding systems: systems: the the Opitz Opitz System System ihe following. following, we discuss and system is 0' interest because because it was was one one of of the the fi first published clasclasrst published and MultiClass. MulliClass. The The Opitz Opitz system or interest sification for mechanical mechanical parts parts [31] (Historical (Historical Note Note 15.1) and and is still sification and and coding coding schemes schemes for still widely acommercial product offered offered by the the Organization Organization for for Industr Industriwidely used. used, MultiClass MulliClass is a commercial product ial Research Research (OIR) (OIR). a!
"

Opitz System. This system system was developed developed by H. H. Opitz Opitz of the UniUniOpitz Classification Classification System. This of the versity represents one one of the pioneering pioneering efforts efforts in group group techversity of Aachen Aachen in Germany. Germany. of the techy It repicsents nology best known, if not the most most frequently frequently used, used, of of the the parts parts iest known, not the nology and and is probably probably the the best knowclassification systems. It is intended intended for for machined machined parts. parts. The The Opitz Opitz coding coding classification and and coding coding system lems. 11 scheme digit sequence: sequence: scheme uses uses thc the following following digit
.

12345

6789 6789

ABCD ABCD

The mne digits, digits, which which can extended by adding four more digits. The basic basic code code consists consists of of nine can be extended adding four more digits. The to convey convey both both design and manufacturing manufacturing data. data. The The interpreinterpreThe first first nine nine arc arc intended intended to design and tation defined in Figure The first first fi five digits, 12345, are called tation of of the the first first nine nine digits digits is defined Figure 15.5. The ve digits, are called thc/onn the primary primary design design attributes attributes of of the part, such such as external shape ihcform code. It It describes describes the the part, external shape (e.g., and machined machined features features (e.g., holes, threads, gear gear teeth, teeth, etc.). etc.]. (e.g., rotational rotational vs. rectangular) rectangular) and holes, threads, the The constitute the the supplementary which indicates indicates some some of of the The next next four four digits, digits, 6789, 6789, constitute supplementary code, code which attributes of use use in manufacturing manufacturing (e.g. (e.g., dimensions, work mater material, starting attributes that that would would be be of dimensions, work ial, starting shape, extra four four digits, digits,ABCD, are referred to as the the secondary secondary code code shape, and and accuracy). accuracy). The The extra ABCD are referred to and the production production operation type and and sequence.The sequence. The secondary secondary and are are intended intended to lo identify identify the operation type code user firm serve its own own particular particular needs. needs. code can can be designed designed by the the user firm to to serve The complex to provide description The complete complete coding coding system system is too too complex provide a comprehensive comprehensive descriptii to obti ol der here, Opitz Opitz wrote wrote an entire entire book e an here. book on on his system system [31]. However However, to to obtain general idea of obtain a general idea of sisting of thie first how the form form code consisting of the first fi five digits, digits. defined defined gengenhow it works, works, let let us examine examine the code consisting the first five erally first digit digit identifies identifies whether whether the the part part is rotational rotational or erally in Figure Figure 15.5. The The first or nonrotational.1t also describes the general shape and proportions of the part. We limit our survey tional.Ilalso describes the general shape and proportions of if the part. pa We limit our survey here possessing no unusual unusual features, those with with first first digit digit values values ofO, here to to rotational rotational parts parts possessing ossessing no features those those with first ofO, 1,
, , , , ,

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Chap.

Chap. 15 15 I / Group Group Technology Technology and and Cellular Cellular Manufacturing Manufacturing
Supplimentary supp~~~m.ry

I)Lgl12 J Digit

D,.i3
Rotot;onRI Rotational machLn"'g

rD,Ki,4
Plane surfau PI."e,urfa<e machlmn.

DtgitS
Addll;onalhob l lh and fo,mlllg

Dipt

Mam shapt

~~:.~,L:~;:~ R
5

I
3

re 15.5 Basic Figu1'f'15.5 the Opitz Basic structure structure of of the Opitz system system of of parts parts classification classification Figjure and d coding. coding.

or2. parts, or2. For For this this etas, class, of of work workparts, Figure 15,6. 15.6. rts, the the coding coding of of the the first first five five digits digits is defined defined in Figure Consider the following Consider the following example example to to demonstrate demonstrate the the coding coding of of a given given part. part. EXAMPLE EXAMPLE 15.1 Opitz Opilz Part Part Coding Coding System Syslei

Given iart design design in Figure Figure 15.7, 15.7, determine determine the the form form code code in the the Given the the rotational rotational part pz Opitz ion and and coding coding system system, Opitz parts parts classification dassificatk Solution: Solution: With With reference reference to Figure Figure 15.6, the the five-digit five-digit code code is developed developed as follows: follows: Length-to-diameter Length-to-diameter ratio, ratio, LID L/D = - 1.5 External Esternal shape: shape: stepped stepped on on both both ends ends with with screw screw thread thread on on one one end end Internal part contains Internal shape: shape, part contains a through-hole through-hole Plane Plane surface surface machining: machining: none none Auxiliary gear teeth, etc.: none Auxiliary holes, holes.gearteeth,etc.:none The system is 15100. The form form code code in the the Opitz Opitz system 15100, MultiClass. MultiClass. MultiClass MultiClass is a classification classification and and coding coding system system developed developed by by the the OrOrganization ganization for Industrial industrial Research Research (OIR). (OIRJ. The The system system is relatively relatively flexible, flexible, allowing allowing the the user and COlling user company company to to customize customize the the classification classification and coding scheme scheme 10 to a large large extent extent to to fit its its own products and applications. Multi Class can be used for a variety of different types own products and applications. MultiClass can used for variety of different types of of manufactured items, including and sheer manufactured items, including machined machined and sheet metal metal parts, parts, tooling, tooling, electronics, eleclronics, purpurDigit = 1 Digit 1 1 = 1 Digit Digit 2 = = 5 Digit == 1 Digit 3 = 1 Digit == 0 Digit 4 = Digit 5 = = 0 Digits

/ Parts Classification and Coding Sec. 15.2 15.2 ! Parts Clessiflcatlon

429
Digit 3
nt rnal ihapc. i","rI:~lc:~:~~.h:I~~"n', is! shape tk-mtnIS
No hole.

_._-Pal'! closs

Digit 4
Plane surface

Digit 5

~~Ji~~a;

t~~;~'

Noauxi~aryhole No auiiiUary hole

as;

No shap

Surface plane.
I
I

cuived in one
diieciion. tslemiil

II~
71
I

L------

1
4

i
J
:}
-

A~:~~ien~:aO;:.;~~Ch

External plane surface

E-ssr
Nf'hape

!
I
4 6

l~'
CLJ

nctional

liD IJL-_.;I,

groove

Spur gear

Functional cone

imernal spline

(polygon)
[ntemaland

Opcranng thread

Operating thread

.1
9
,

Figure Figure 15.6 15.6 Form Form code code (digits 1-5) rotational parts parts in the the Opitz le (digits 1-5) for for rotational Opit/ coding system. The first first digit digit of of the the Code code is limited limited to to the the value value 0 0, coding 5' lystem. The l or2. 1.0r2.
,

000
.

fJ13.'C~
-O SOO-H
. .

__ . _

--

-----r --.l I
-

1X10

0.250

0.750

1-g~=I~T
0 875 L5(XI---J

1 Figure 15.7 Part Part design design for for Example 15.1. Figure Example 15
.

430

Chap. 15 / I Group Group Technology Technology and Cellular Cellular Manufacturing Chap. and Manufacturing

chased pam, assemblies subassemblies, machine machine tools, and other other elements. elements. Upton, Up to nine chased pans, assemblies and and subassemblies, lools, and U| include within different of components components can be included included MultiClass software different types (if within a single single MuitiClass software structure structu Multif.lass uses uses a hierarchical hierarchical or or decision-tree decision-tree coding structure in which which the sucMultiClass coding structure ceeding digits digits depend depend on on values values of of the the previous previous digits. In the the application application of of the the system, system, a ceeding digits In series of of menus, menus, pick pick lists, lists, lables, tables, and and other other interactive prompting routines routines are are used code series ii active used to code ve prompting prompl provide discipline to the coding procedure. the part. part This helps to organize and provide procedure. The coding consists of up to to 30 digits. digits. These These are divided into into two two regions, regions, The coding structure structure consists of up are divided dividei region: >cific needs needs and rere one designed by the the user to meet meet specific specific and le provided provided by GIR, OIR, and the second second designed user to spe ne :edes the quirements. prefix precedes the code number and and is used used to identify identify the the type type of lirements. A prefix quin precedes code number c part par part ; a prefix (e.g., prefix value and sheet metal parts). For a machined machined part, value of 1 1 indicates indicates machined machined and sheet metal parts). For ed part, pari the the coding first 18 digit digit positions positions (after (after the prefix) summarized in Table ig for the first prefix) is summarized Table 15.2.
"

TABLE 15.2 15.2 TABLE

digits of the Murtretess First 18 digits Multiclass Classification Classification

and Systam and Coding Coding System

Digit
0 o

Function Code system preflx Code system prefix Main shape shape category category External internal configuration External and and internal configuration
Machinedsecondary lernents Machined secondary ulements

1
2 3 2,3 4
,

5 6 5,6 7 -12 7-12 13 13

,

Functional descriptors Functional descriptors Dimensional !length, diameter diameter, etc.) Dimensional data data llength,
,

Tolerances Tolerances

14, 15 14,15 16 16

17 18 18 EXAMPLE 1S.2 15.2 EXAMPLE

Material chemistry chemistry Raw material material shape shape Production quantity Production quantity Machined element orientation orientation Machined element

MuitiClass Coding Coding System System MuitiClass

.

p Given rotational part part design design in Figure Figure 15.8, the 18-digit IS-digit code code in Given the the rotational 15 8 determine determine the the MultiClass MuitiClass parts parts ci :oding system system. Ihe coding
,
~

0 352 0.003 dia

.

r ;oowru.

5i16-18UNC2A(2) 5/16-18UNC2A (2)

@ AO.MST.I.R. |

-1@ AO.OIOdia

|I

Umax (2)

o.oi5 0;ml>R.B) O.0l5~~::R(2J

_

-8:---0 mi-j JR 1 l,02

-

0 080
.

0.030 x 45 |2)

I
Fig~lre 15.8 Workpart Figure 15.8 Workpart of of Example Example 15.2. 15 2 (Courtesy (Courtesy of OIR, OIR OrganiOrganization for Industrial zeuon Industnal Research Research.) )
. .

Sec. FlowAnalvsis Sec. 15.3 15.3 / ! Production Production Flow Analysis

Dimcnuons

43'

iufacBinnj;

Materia!

18

19

20

Code

sccomlarv

Ts r
,
,

L-lemcnls (holes

j
L
-

Thread

visible lYom .

inside

p
lJu"l(l~ataIl1~lcr range 0251-D.J7Iin

a groove

Figun: 15.9 15.9 MultiClass MultrClass code code number number determined determined for for part part in ExamExamFigurt ple 15.2. (Courtesy (Courtesy of OIR, Organization Organization for Industrial Research.] for Industrial Research.) pie 15.2. 15 of OIR
,

Solution: The MultiClass Multi'Class code code number number for for the the given given part developed in Figure Figure 15.9. Solution: The part is developed

75.3 15.3

PRODUCTION PRODUCTION FLOW FLOW ANALYSIS ANALYSIS This This is approach to identification and and machine cell tormation formation that picis an an approach to part part family tamily identification machine cell that was pio-

necred Burbidge [6]-[8\. [6]-[R].Productionflow analysis (PFA) (PFA) is isa method for identifying sd by J. Burbidge Production flow analysis a method for identifying part families families and and associated associated machine machine groupings that uses uses the the information information contained contained on 011 groupings that production route sheets sheets rather rather than than on part drawings. Workparts Work parts with identical or or similar similar iction route part drawings. with identical routings classified into into part part families. families. These These families families can can then then be used used to to form form logical logical mamaigs are are classified chine cells cells in a group group technology technology layout. layout. Since PFA uses manufacturing data data rather rather than than Since PFA uses manufacturing design i data data to identify can overcome overcome two possible anomalies that can can occur design identify part families, families lily part families, it can two possible anomalies that occur parts classification classification and coding. First, parts parts whose whose basic basic geometries geometries are quite different may in parts cation and coding. First First, geomt are quite different may nevertheless :quire similar nevertheless rei require similar or even even identical identical process process routings. routings. Second, Second, parts parts wh whose georne. lat or lose geoi tries are quite similar similar may may nevertheless require process routings routings that that are are quilt quite different. routii ly nevertheless require process The The procedure in production production flow flow analysis analysis must must begin begin by defining defining the scope of of the the The procedure the scope study, whicl study, which which means means deciding deciding on on ihe the population population of parts to to be be analyzed analyzed. Should Should all all of of the the of parts parts in snop he be included Included in the the study, study, or sample be be selected selected parts in the the shop study or should should a representative represen representative sample for this decision for analysis? analysis! Once Once this decision is made made, then then the the procedure in PFA PFA consists consists of of the the folfolprocedure in lowing steps: lowing steps:
, ,
.

432

Chap, 15 Group Technology and Cellular Manufacturing Chap. 15 // Group Technologv and Cellular Manufacturing

1 1. Data The minimum minimum data needed in the the analysis analysis are the part part number and Daia collection. collection. The data needed are the number and
.

operation sequence, which which is contained contained in shop shop documents documents called called route sheets or or op)eration sequence, route sheets cratii eration sheets or some some similar similar name. operation is usually associated with with a parparsheets or name. Each Each operation usually associated ticulE iiachine so ticular machine, so determining determining the the operation operation sequence also determines determines the machine sequence also the machine lence. Additional aslol size,itime sequence.Additional data.such 101size, time standards,and standards, and annual annual demand might such as lot size, demand might sequence. Additional data data be useful for designing machine cells of the required required production production capacity. capacity. 2 Sanation 2. Sonatton of of process process routings. routings. In In this this step, the parts parts are arranged into into groups groups ai acstep, the are arranged cording to the similarity similarity of of their their process process routings. routings. To facilitate this step, operations cording to the facilitate this step, all operatior or machines machines included included in the the shop shop are are reduced to code code numbers, numbers, such such as those those shown shown or reduced to Table 15.3. For For each each part part, the operation codes codes are listed in the the order order in which which they they the operation are lisled in Table rocedur is then are performed. performed. A A sortation sortation procedure procedure used to to arrange arrange parts parts into into "packs," packs, are then used which are are groups of of parts parts with with identical identicalal routings. routings. Some Some packs packs may contain only only one one which ire groups may conlain part number, number, indicating the uniqueness the processing that part. part. Other Other packs packs will part indicating the uniqueness of the processing of of that contain many many parts parts, and and Ihese these will constitute constitute a part part family. family. contain
, ,
.

"

"

3 3.
.

PFA chart. The The processes processes used used for for each each pack are then displayed in a PFA PFA chart, chart, a sun. PFA chart. pack are then displayed plified example example of of which which is illustrated illustrated inTable in Table 15.4. 15.4.1lThe The chart chart is a tabulalion tabulation of the the plified process or or machine machine code code numbers numbers for the part part packs. packs. In recent literature [30], process for all of the recent GT GT literature mathe PFA PFA chart chart has has been referred to to as part-machine part-machine incidence matrix matrix. In In this this rna. the been referred incidence trix = or 0: a value - 1 indicates that the corretrix, the the entries entries have have 3 a value value x,, Xii = 1 lor value of of X;j = 1 indicates that the sponding part part / i requires requires processing processing on on machine and X'I = 0 indicates that no no spending machine j, and indicates that processing of component i is accomplished accomplished on machine machine j. For clarity of of presenting processing of component For clarity presenting the the matrix matrix, the the 0's D's are often indicated indicated as blank blank (empty) our table. table. are often (empty) entries, entries, as in our
.

4 4.

Cluster analysis. analysis. From the pattern pattern of of data data in the the PFA PFA chart chart. related related groupings groupings are are Cluster From the
,

identified and and rearranged into a new ncw pattern pattern that that brings brings together packs with similar identified rearranged into together packs with similar machine sequences. One possible possible rearrangement rearrangement of PFA chart shown machine sequences. One of the the original original PFA chart is shown
in Table 15.5 where Table 15.5, where differenl different machine groupings are indicated within within blocks. machine groupings are indicated blocks The The
,

blocks possible is possib blocks might might be be considered considered as possible machine machine cells cells. It It is often the case case (but (but not not in often the
.

Table some packs packs do do not not fit into into logical groupings. These These parts parts might might be be ananTable 15.5) that that some logical groupings alyzed to to see if a revised revised process sequence can be be developed into one one of of the the ed process sequenci can alyzed sequence developed that that ffits its into
.

groups. If not, not, these these parts parts must must continue continue to to be fabricated through through a conventional conventional groups. be fabricated process layout. layout. In In Section Section 15.6.1, we examine systematic technique called rank rank order order process examine a systematic technique called dusterlnR that can can be be used used to to perform perform the the cluster cluster analysis analysis. cluste ring that TABLE 15.3 15.3 TABLE
.

Possible Code Code Numbers Numbers Indicating indicating Possible Operations Operations and/or and/or Machines Machines for for Sortation in Production Flow Analysis Analysis Sortation Production Flow (Highly Simplified) (Highly Simplified)
Code Code 01 01
02 02

Operation or Machine Machine Operation

Cutoff Cutoff

Lathe Lathe

Turret Turret lathe lathe Mil' Mill Drill: manual Drilf:manual NC drill NCdri/i Grind

03 03 M 04 05

ee

07 07

phabellc character cbracter and machines machInes by number. number. In practice, number, would be be nsed phabetic and In practice, rambers would used flor or both both.

1l F ot clarity the part-machine incidence rices and For clarity in in the p~-machine incidence mat matrices and related related discussion discussion, we we are identifying parts parts by by alare identifying al,

Sec. 15.3 15.3 / / Production Production Flow Flow Analysis Analysis Sec. TABLE 15.4 15.4 TABLE PFA Chart, Chart, Also Also Known Known as as a a Part-Machine Part-Machine Incidence Incidence Matrix Matrix PFA
Parts Parts

433 43'

Machines Machines
1

ABCDEFGHI

2 3

6
7

TABLE TABLE 15.5 15.5

Rearranged Rearranged PFA PFA Chart. Chart, Indicating Indicating Possible Possible Machine Machine Groupings Groupings

Parts Parts Machines Machines CE IADHFGB A

3 2 6 1 5 7 4

, ,
1 1

, ,
1 1

,
1

1 1
1

, ,

, , , ,
1 1 1
1
,

The The weakness weakness of of production production flow flow analysis analysis is that that the the data data used used in the the technique technique are are these route route sheets sheets have have derived derived from from existing existing production production route route sheets. sheets. In all likelihood, likelihood these been prepared by different been prepared different process process planners, planners, and and the the routings routings may may contain contain operations operations that that are optimal, illogical, machine groupings are non nonoptimal, illogical, or or unnecessary. unnecessary. Consequently, Consequently the the final final machine groupings obob,

PFA has has the the tained in the tained the analysis analysis may may be be suboptimal. suboptimal. Notwithstanding Notwithstanding this this weakness, weakness PFA virtue requiring less virtue of of requiring less time time than than a completc complete parts parts classification classification and and codmg coding procedure. procedure This This virtue virtue is attractive attractive to to many many firms firms wishing wishing to to introduce introduce group group technology technology into into their their plant operations. plant operations.
,
.

434
15.4 CELLULAR CELLULAR MANUFACTURING MANUFACTURING

Chap. 15 / Group and Cellular Cellular Manufacturing Chap. Group Technology Technology and Manufacturing

Whether part have been been determined determined by by visual visual inspection, inspection. parts parts classification and Whether part families families have classification and coding, or or production production fl flow analysis, there there is advantage producing those those parts parts usinggroup using group coding, ow analysis, advantage in producing technology machine machine cells cells rather rather than than a traditional traditional process-type process-type machine When the the technology machine layout. layout. When machines are the term cellular manufacturing manufacturing is used used to descr describe this work work orgaorgamachines are grouped. grouped, the term cellular ibe this nization. Cellular Cdlular manufacturing manufacturing application of group technology technology in which dissiminization. is an an application of group which dissimilar machines machines or or processes processes have have been been aggregated into cells, cells, each each of of which which is dedicated dedicated to the the lar aggregated into production of of a pari product family family or or a limited limited group of families families. The typical objectives objectives production pan or or product group of The typical cellular manufacturing manufacturing are are similar similar to to those those of of group technology: in cellular group technology: To shorten shorten mantt manufacturing lead limes times, by reducing reducing setup, setup, workpart workpart handling, handling, waiting waiting . facturing lead
,

times, batch sizes. times, and and batch sizes lead times To reduce reduce work-in-process inJ!enIOry. Smaller Smaller batch batch sizes sizes and and shorter shorter lead times rere. work-in-process inventory duce work-in-process. work-in-process. duce
.

To improve tmprove quality quality. This This is accomplished accomplished by allowing allowing each each cell cell to to specialize pro. specialize in producing a smaller smaller number number of different different parts. parts. This reduces process process variations. variations. ducing This reduces To simplify simplify production production scheduling. The similarity similarity among among parts parts in the family reduces . scheduling The the family reduces the complexity complexity of production production scheduling. scheduling. Instead Instead of of scheduling scheduling parts parts through through a sethe inplexity of I quence machines in a process-type layout, the parts are are simply simply scheduled scheduled lence of of machines process-type shop shop layout, the parts quenct
. .

'

though the the cell. though cell. To reduce reduce setup setup times times. This This is accomplished accomplished by by using using group (cutting tools, tools, group tooling (cutting roup tooling too fixtures) that that have been designed designed to to process process the part family, family, rather rather than jigs, gs, and and fix fixtures) have been the part than part part tooling, designed for for an individual mdividual part. part. This This reduces number of of indiinditooling, which is designed reduces the the number Doling, which wh vidual tools tools required required as well well as the the time time to change tooling tooling between between parts. parts. vidual to change
.

Additional reasons for implementing cellular manufacturing are given given in Table Table 15.7. In Additional reasons for implementing cellular manufacturing are this section, section, we consider consider several several aspects aspects of cellular manufacturing manufacturing and and the the design design of mamathis of cellular
chine cells. chineceils.

15.4.1 15.4.1

Composite Part Concept Composite Part Concept

Part families families are are defined the fact fact that that their their members members have have similar similar design design and/or manuPart defined by the and/or manufacturing features. features. The The composite composite part part concept concept takes takes this part family family definition definition to to its logilogifacturing this part conclusion. It of a hypothetical hypothetical part, part, a composite composite part part for for a given given family, family, cal conclusion. It conceives conceives of which includes includes all of of the design and and manufacturing manufacturing attributes of the the family. family. In In general general. an an which the design attributes of individual part part in the family will have some some of of the the features features that that characterize characterize the family but but individual the family will have the family not all of them. The part possesses possesses all of of the features. not of them. The composite composite part the features There is always always a correlation correlation between between part part design features and and the the production production opopThere design features erations required required to 10 generate generate those those features. features. Round Round holes holes are made by by drilling drilling, cylindrical erations are made cylindrical shapes are are made made by turning, turning, flat flat surfaces surfaces by by milling, milling, and and so so on. on. A production designed shapes production cell designed for the the part would include include those those machines machines required required to to make make the the composite composite part part. Such Such for part family family would 11 would would cell would be capable capable of of producing any member member of of the family, simply by omitting omitting those those a cell producing any the family simply by cell would operations corresponding corresponding to to features features not not possessed possessed by by the the particular particular part part. The The cell would operations also be be designed allow for for size variations within the family family as well well as as feature also designed to allow size variations within the feature variations. variations illustrate, consider consider the composite part part in in Figure Figure 15 15.1O(a).1l represents a family of To illustrate, the composite 10(a). It represents family of re is a rotational parts parts with with features features defined defined in Figure Associated with with each each featu feature rotational Figure 15.1O(b). 15.10(b) Associated certain machining operation as summarized in Table 15.6. A machine cell to produce this
,

Sec. 15.4

Sec. 15.4 l; Cellular Cellular Manufacturing Manufactumg

435 43'

ciins.fsiinj! ..if 3)1

seven Sevgn :-.nJ
ct'Mingait'iburcs

"

;:=- Ge:
U)

Ibl

Figure 15.10 1S.10 Composite Composite part part concept: concepl: (a) (a) the the composite composite part part for for a Figure

family of of machined machined rotational rotational parts parts and and (b) (b) the the individual individual features features family of the the composite composite part. part. See See Table Table 15.6 15.6 for for key key to to individual individual features features of and corresponding corresponding manufacturing manufacturing operations. operations. and

TABLE 15.6 15.6 TABLE

Design Features Features of of the the Composite Composite Part Part in in Figure Figure 15.10 15.10 and and the the Design
Manufacturing M;inufacluring Operations Operations Required Required to (o Shape Shape Those Those Features Featuree

Label Label
1 2

Design Feature Feature Design

Enternal cylinder Externalcylinder Cylinder teca face Cvtlnder Cylindrical step step Cylindrical Smooth surface surface Smooth Axial hole hole Axial Counterbore Counterbore Internal threads threads Internal

Corresponding Manufacturing Manufacturing Operation Operation Corresponding

Turning Turning Facing Facing Turning Turning

3 4 5 6 7

External cylindricaf cylindrical grinding grinding External Drilling Drilling Counterboring Counterboring Tapping Tapping

part family family would would be be designed designed with with the the capability capability to to accomplish accomplish all all seven seven operations operations rerepart quired to to produce produce the the composite composite pan part (the (the last last column column in in the the table). table). To To produce produce a a specific specific quired member of of the the family, family, operations operations would would be be included included to to fabricate fabricate the the required required features features of of member the part. part. For For parts parts without without all all seven seven features, features, unnecessary unnecessary operations operations would would simply simply be be the omitted. Machines, Machines fixtures, fixtures, and and tools tools would would be be organized organized for for efficient efficient flow flow of of workparls workparts omitted. through through the ihe cell, cell. In practice, pracLice. the the number number of of design design and and manufacturing manufacturing attributes allribules is is greater greater than than seven, seven In and allowances allowances must musl be be madc made for for variations variations in in overall oveiall size size and and shape shape of of the the parts parts in in the the famfamand ily. Nevertheless, Nevertheless, the the composite composite part part concept concept is is useful useful for for visualizing visualizing the the machine machine cell cell dedeily. sign sign problem. problem.
,
.

15.4.2 15.4.2

Machine Cell Cell Design Design Machine

.

Design of of the the machine machine cell cell is is critical critical in in cellular cellular manufacturing. manufacturing The The cell cell design design determines determines Design to a a great great degree degree the the performance performance of of the the cell. cell. In In this this subsection, subsection we we discuss discuss types types of of machine machine to cells, cells, ceJllayouts, cell layouts, and and the the key key machine machine concept. concept.
,

436

Chap. Chap. 15 15 // Group Group Technology Technology and and Cellular Cellular Manufacturing Manufacturing

Types of manufacturing cells be classified classified of Machine Machine Cefls Cells and and Layouts. Layouts. GT GT manufacturing cells can can be according according to to the the number number of machines machines and and the the degree degree to to which which the the material material flow flow is mechmechanized between machines. anized between machines. In In our our classification classification scheme scheme for for manufacturing manufacturing systems systems (Section (Section 13.2), cells are of part 13.2), all GT GT cells are classified classified as type type X in terms terms of part or or product product variety variety (Section (Section 13.2.4, Table we identify Table 13.3). Here Here we identify four four common common GT GT cell cell configurations configurations (with (with system system type type idenidentified tified in parenthesis parenthesis from from Section Section 13.2):
1 single 1. single machine machine cell cell (type (type I 1 M) 2 group 2. group machine (type n machine cell cell with with manual manual handling handling (type TT M generally, generally, type type III III M less common) common)
. .

3 group 3. )up machine machine cell cell with with semi-integrated semi-integrated handling handling (type (type II M generally, generally, type type III III M group CO less is common) common)
.

4 flexibie 4. flexible manufacturing manufacturing cell cell or or flexible flexible manufacturing manufacturing system system (type (type IT II A A generally, generally, type III type III A A less common) common)
,

As its As its name name indicates, indicates, the the single single machine machine cefl cell consists consists of of one one machine machine plus plus supportsupporting ing fixtures fixtures and and tooling. tooling. This This type type of of cell cell can can be be applied applied to to workparts workparts whose whose attributes attributes allow allow them them to be be made made on on one one basic basic type type of of process, process, such such as turning turning or or milling. milling. For For examexample, could be on a conventional ple, the the composite composite part part of of Figure Figure 15.10 could be produced produced on conventional turret turret lathe, lathe, with with the the possible possible exception exception of of the the cylindrical cylindrical grinding grinding operation operation (step (step 4) 4). The handling is an an arrangement The group group machine machine cell cell with with manual manual handling arrangement of of more more than than one one machine There is no provision machine used used collectively collectively to to produce produce one one or or more more part part families. families.There provision for for mechanized the human mechanized parts parts movement movement between between the the machines machines in in the the cell. cell. Instead, Instead the human operaoperators tors who who run run the the cell cell perform perform the the material materia] handling handling function. function. The The cell cell is often often organized organized into into a Ij-ehaped U-shaped layout, layout, as shown shown in Figure Figure 15.11. This This layout layout is considered considered appropriate appropriate when among the parts made cell. It also when there there is variation variation in the the work work flow low among the parts made in the the cell. also allows allows the the multifunctional multifunctional workers workers in the the cell cell to to move move easily easily between between machines machines [29]. [29], The is sometimes The group group machine machine cell with with manual manual handling handlingis sometimes achieved achieved in a conventional conventional process process type type layout layout without without rearranging rearranging the the equipment. equipment. This This is done done simply simply by assigning assigning certain machine group restricting their certain machines machines to to be be included included in the the machine group and and restricting their work work to to specispecified cellular manufacturing fied part part families. families. This This allows allows many many of of the the benefits benefits of cellular manufacturing to to be be achieved achieved without in the without the the expense expense of of rearranging rearranging equipment equipment in the shop. shop. Obviously, Obviously the the material material handling handling benefits organization. benefits of of OT GT are are minimized minimized with with this this organization.
,

Workout

Work in Work

Proc

Hroc

JQ3

Maaualbandling iiial handling een machines between machines

f?

& Man

Proc

. 9

Proc Man

Proc

Man

Figure Figure 15.11 Machine Machine cell with with manual manual handling handling between between machines. machines Shown layout. (Key: Shown is is a a If-shaped U-shaped machine machine layout. (Key. "Proc" "Proc" = processing processing operation operation; arrows operation (e.g., (e.g., mill. mill, turn, turn, etc.), etc.), "Man" "Man" = = manual manual operation; arrows indicate indicate work work flow.) flow.)
.

0=

Sec. Sec. 15.4 / Cellular Cellular Manufacturing Manufacturing

437 437

The group group machine machine cell cell with with semi-Integrated semi-integrated handling uses uses a mechanized mechanized handling handling The handling

/Ie:i6/emansystem, such such as a conveyor, conveyor, to to move move parts parts between machines in the the cell.The cell. Theflexible mansystem, between machines
_

ufacturing system system (FMS) integrated material material handling handling system with autoautoufacturing (FMS) combines combines a fully fully integrated system with mated processing processing stations. The FMS FMS is the the most most highly highly automated the group mated stations. The automated of of the group technology technology machine cells. The The following following chapter chapter is devoted devoted to to this form of of automation, automation, and and we defer defer machine this form
discussion discussion till till then. then.

A variety of of layouts layouts are are used used in GT GT cells, The Ucshape, as as in Figure Figure 15.11, is a popupopuA variety The U-shape, lar configuration configuration in cellular cellular manufacturing. manufacturing. Other in-line, loop, and lar Other GT GT layouts layouts include include in-line, loop, and rectangular, in Figure Figure 15.12 15.12 for for the the case case of semi-integrated handling. handling. [angular, shown shown in of semi-integrated

Mechanize Mechanized ed
.

work handli Work in

*.* [

Work

p ~" ~~
(oj (a)

g
Mechanized wo~khandling

w;;;:; ( OOJ

Work in Wmbo

...
P*3 AA
<OT
VO\I

7<

Us u
(b) (bj

--... ~ ---...
Work in

P'::"R:;::WO'k,,",dliO' [;ill @ill

~ \'t ~

Mechanlzed

Work in

Work out WorkDut

tcri OOJ

OOJ ion

@3
(,j

Figure 15,12 15.12 Machine with semi-integrated Figure Machine cells cells with semi-integrated handling: handling: (a) (a) inin-

line i line layout layout, (b) (b) loop loop layout, layout, and and (c) (c) rectangular layout. (Key' rectangular layout. (Key: Proc" "Proc'' = processing processing operation mill,turn, etc.]. "Man" "Man" = man. Proc" = operation (e.g., (e g mill, turn, etc), = man, "
. .,

ual operation; operation; arrows arrows indicate indicate work work flow now) ) ual indi
.

438 438
(1) Repeal (1)Repeal

Chap.

Chap. 15 15 I / Group Group Technology Technology and and Cellular Cellular Manufacturing Manufacturing

Optra lion

Q l iKl |!C|
OP""';OP

(3) By-passing m-

(3)8,_p.".gmo'O

"~""""~"~
Man Man (4) Backtracking (4) Backtracking move

Man (I) n-sequence In-sequence

Man

Figure Figure 15.13 15.13 Four Four types types of of part part moves moves in in a a mixed mixed model model production production system. system. The The forward forward flow flow of of work work is from from left left to to right. right.

Determining cell layout depends on Determining the the most most appropriate appropriate cell layout depends on the the routings routings of of parts parts proproduced Four types duced in the cell. cell. Four types of of part part movement movemeni can can be be distinguished distinguished in a mixed mixed model model part part production system. They are production system-They are illustrated illustrated in Figure Figure 15.13 15.13 and and are are defined defined as follows, follows, where where direction of work flow is is defined defined as a~heing figure:(l) the forward direction heing from left left to right in the figure: (1) rerepeat operation, in which peal operation, which a consecutive consecutive operation operation is carried carried out out on on the the same same machine, machine, so that that the move, the part pari does does not not actually actually move; move; (2) in-sequence in-sequence move, in in which which the the part part moves moves from from the the setfuen current current machine machine to to an an immediate immediate neighbor neighbor in the the forward forward direction; direction; (3) (3) by-passing by-passing move, mo ve, in which which the part part moves moves forward forward from from the the currenl current machine machine to to another another machine machine that that is two two or machines ahead; part moves or mort more machines ahead; and and (4) backtracking backtracking move, move, in which which the the part moves from from the the curcurrent machine machine in the the backward backward direction direction to to another another machine. machine. rent When in-sequence moves, When the the application application consists consists exclusively exclusively of of in-sequence moves, then then an an in-line in-line laylayout out is appropriate. appropriate. A A V-shaped U-shaped layout layout also also works works well well here here and and has has the the advantage advantage of of closcloser the cell. er interaction interaction among among the the workers workers in the cell. When When the the application application includes includes repeated repeated operations, multiple stations operations, then then multiple stations (machines) (machines) are are often often required. required. For For cells cells requiring requiring bybypassing passing moves, moves, the the Li-shape U-shape layout layout is appropriate. appropriate. When When backtracking backtracking moves moves are are needed, needed, a loop loop or or rectangular rectangular layout layout is appropriate appropriate to accommodate accommodate recirculation recirculation of of parts parts within within the the cell. cell. Additional Additional factors factors that that must must be be accounted accounted for for in in the the cell cell design design include: include:
-

cdt. This . Quantity Quantity of of work work to to be be done done by by the the cell This includes includes the the number number of of parts parts per per year year and the part at and the processing processing (or (or assembly) assembly) time time per per part at each each station. station. These These factors factors deterdetermine the mine the workload workload that that must must be be accomplished accomplished by by the the cell eel! and and therefore therefore the the number number of of the of machines machines that that must must be be included, included, as well well as total total operating operating cost cost of the cell cell and and the the investment investment that that can can be be justified justified..
.

. Part Fart size, size shape, physical attributes. shape, weight, weight, and and other other physical attributes. These These factors factors determine determine the the size size and and type type of of material material handling handling and and processing processing equipment equipment that that must must be be used. used.
,

Key Machine GT machine Key Machine Concept. Concept. In some some respects, respects a GT machine cell cell operates operates like like a man. manual assembly line (Chapter desirable to to spread assembly line (Chapter 17), 17) and and it is desirable spread the the workload workload evenly evenly among among the the
, ,

machines in the the cell as the other machines as much much as possible. possible. On On the other hand, hand there there is typically typically a certain certain rnamachine in a cell (or (or perhaps perhaps more chine more than than one one machine machine in in a large large cell) cell) that that is more more expensive expensive
,

to than the the other other machines certain critical io operate operate than machines or or that that performs performs certain critical operations operations in the the plant plant This It is important This machine machine is referred referred to as the the key key machine. machine It important that that the the utilization utilization of of this this
. .

Sec, 15.5 / I Application Sec. Application Considerations Considerations in Group Group Technology Technologv

439

key key machine machine be be high. high, even even if il it it means means that that the the other other machines machines in in the the cell cell have have relatively relatively low low be utilization. machines, and utilization. The The other other machines machines are are referred referred to as.mpporting as supporting machines, and they they should should be organized organized in the the cell to to keep keep the the key key machine machine busy. In a sense, sense, the the cell cell is designed designed so that that the the system. the key key machine machine becomes becomes the the bottleneck bottleneck in the system. The machine concept The key key machine concept is is sornetnues sometimes used used to to plan plan the the GT GT machine machine cell. cell. The The apapproach processed through proach i~ i!. to to decide decide what what parts parts should should be be processed through the the key key machine machine and and then then dedetermine termine what what supporting supporting machines machines are are required required to complete complete the the processing processing of of those those parts. parts. There There are generally generally two two measures measures of of utilization utilization that that are are of of interest interest in a GT GT cell: the the utilization utilization of of the the kev key machine machine and and the the utilization utili/.ation of the the overall overall cell. cell. The The utilization utilization of of the the key (Section 2.4.3). key machine machine can can be'measured be measured using using the usual usual definition definition (Section 2.4.3). The The utilization utilization of of each of the other machines can also be evaluated similarly. The cell utilization is obtained each of the other machines can also evaluated similarly. The utilization obtained by One of the by taking taking a simple simple arithmetic arithmelic average average of of all the machines machines in the the cell. cell. One the exercise exercise problems the end the chapter problems at the end of of the chapter serves serves 10 to illustrate illustrate the the key key machine machine concept concept and and the the dedetermination of of utilization utilization. termination

15.5 15.5

APPLICATION CONSIDERATIONS IN IN GROUP GROUP TECHNOLOGY TECHNOLOGY APPLICATION CONSIDERATIONS

this section, section WP, In this we. ,~onsider consider how how and and where where group group technology technology is applied, applied, and and we report report on on the the United the results results of a survey survey of of industry industry ahout about cellular cellular manufacturing manufacturing in the United States States [38] [38],
,

15.5.1 15.5.1

Applications of Group Applications Group Technology Technology

,

Tn our introduction to this In our introduction this chapter, chapter we defined defined group group technology technology as a "manufacturing "manufacturing phiphilosophy." GT is not losophy." GT not a particular particular technique, technique although although various various tools tools and and techniques, techniques, such such as
,

parts parts classification classification and and coding coding and and production production flow flow analysis, analysis, have have been been developed developed to to help help implement implement it. The The group group technology technology philosophy philosophy can can be applied applied in a number number of of areas, areas. Our Our discussion on the discussion focuses focuses on the two two main main areas areas of of manufacturing manufacturing and and product product design. design. Manufacturing most common Manufacturing Applications. Applications. The The most common applications applications of of GT GT are are in manmanufacturing. ufacturing, And And the the most most common common application application III in manufacturing manufacturing involves involves the the formation formation of of cells of one cells of one klnd kind or another, another. Not Not all companies companies rearrange rearrange machines machines to lo form form cells. tells. There There are are three three ways ways in which which group group technology technology principles principles can can be be applied applied in manufacturing manufacturing [24]:
1 Informal 1. of similar through selected Informal scheduling scheduling and and routing routing of similar parts parts through selected machines. machines. This This, approach part families approach achieves achieves setup setup advantages. advantages but but no no formal formal part families are are defined, defined, and and no no physical physical rearrangement rearrangement of of equipment equipment is undertaken. undertaken.
.

2 Virtual 2. Virtual machine machine celkThis ceWs.This approach approach involves involves the the creation creation of part part families families and and deddedication equipment to the ication of equipment the manufacture manufacture of of these these part part families, families but but without without the the physphysthe virtual virtual cell cell ical rearrangement of machines machines into into formal cells The ical rearrangement of formal cells. The machines machines in the Use of virtual cells seems to facilitate remain in their original locations in the factory. Use of virtual cells seems to facilitate remain their original locations the factory the the sharing sharing of of machines machines with with other other virtual virtual cells cells producing producing other other part part families families [25J. [25]
.

3 Formal 3. Formal machine machine cells. This is the cetls.This the conventional conventional GT GT approach approach in which which a group group of of disdissimilar machmes similar machines are are physically physically relocated relocated into into a cell that that is dedicated dedicated to the the producproduction of of one The machines tion one or a limited limited set set nfp:lTI of part families families (Section (Section 15.4.2). 15 4 2).The machines in a formal formal ~achine cell machine cell are are located located in close close proximity proximity to minimize minimize part part handling, handling throughput throughput time, setup time, time and nrne.serup and work-in-process. work-in-process.
.

440

Chap. Chap. 15 15 // Group Group Technology Technology 311d and Cellular Cellular Manufacturing Manufacturing

Other Other GT GT applications applications in in manufacturing manufacturing include include process process planning planning (Chapter (Chapter 25), 25), famfamily ily tooling, tooling, and and numerical numerical control control (NC) (NC) part part programs. programs. Process Process planning planning of of new new parts parts can can be of part The new be facilitated facilitated through through the the identification identification of part families. families.The new part part is associated associated with with an an existing the process existing part part family. family, and and generation generation of of the process plan plan for for the the new new part part follows follows the the routrouting other members ing of of the the other members of of the the part part family. family. This This is done done in in a formalized formalized way way through through the the use of parts classification and coding. in the context of auto coding. The approach is discussed in mated mated process process planning planning (Section (Section 25.2.1). 25.2.1). the ideal, ideal all In the all members members of of the the same same part part family family require require similar similar setups, setups, tooling, tooling, and and fixturing. in the fixturing. This This generally generally results results in a reduction reduction in the amount amount of of tooling tooling and and fixturing fixturing needneededInstead determining a special kit for ed. Instead of of determining special tool tool kit for each each part, part, a tool tool kit kit is developed developed for for each each part The concept part family. family.The concept of a modular modular fixture fixture can can often often be be exploited, exploited, in which which a common coinmon base fixture is designed base fixture designed and and adaptations adaptations are are made made to to switch switch between between different different parts parts in the the family family. A A similar similar approach approach can can be be applied applied in NC NC part part programming. programming. Called Called parametric parametric propro/lTamming. of a common gramming, [28], it involves involves the the preparation preparation common NC NC program program that that covers covers the the enenpref lire family. The tire part part family. The program program is then then adapted adapted for for individual individual members members of of the the family family by by inserting inserting dimensions dimensions and and other other parameters parameters applicable applicable to to the the particular particular part. part. Parametric Parametric programming and setup programming reduces reduces both both programming programming time time and setup time. time.
,

Product Design Design Applications. Product Applications. The The application application of of group group technology technology in product product design design is found found principally principally in the the use use of of design design retrieval retrieval systems systems that that reduce reduce part part prolifproliferation eration in the the firm. firm. It It has has been been estimated estimated that that a company's company s cost cost to to release release a new new part part dedesign sign ranges ranges between between $2000 $2000 and and $12.000 $12,000 [37]. [37], In In a survey survey of of industry industry reported reported in [36], [36], it was was concluded concluded that thai in in about about 20% 20% of of new new part part situations, situations, an an existing existing part part design design could could be be used. part design used. In about about 4(J% 40% of of the the cases, cases, an an existing existing pari design could could be be used used with with modifications, modificationf. The the cost The remaining remaining cases cases required required new new part part designs. designs. If If the cost savings savings for for a company company gengendbe erating be crating 1000 1000 new new part part designs designs per per year year were were 75% 75% when when an an existing existing part par part design design could could be 'ouid still still be some of associated \ used (assuming that cost oftime rat there there would would still be be some some cost cost of time time associated associated with with the the new new part part Id be be for engineering analysis design retrieval) retrieval) and and 50% 50% when when an an existing existin nalysis and andI design existing design design could could be and modified, modified, then then the the total total annual annual savings savings to to the the company company would would lie between between $700,000 $700 000 and $4,200,000, $4,200,000, or or 35% of of the the company's company's total total design design expense expense due due to to part part releases. releases. The The kinds kinds Mosl of an efficient efficient design of design design savings savings described described here here require require an design retrieval retrieval procedure. procedure Most part retrieval procedures parts classification and part design design retrieval classific; procedures lin: are based based on on parts classification and coding coding systems system (Section 15.2). (Section 15.2). Other design applications of group technology involve simplification and standardOther design applications of group technology involve simplification and standardters, such inside radii radii on on corners, corners, chamfer chamfer sizes sizes on outoutization ization of of design design parameters, parameters, such as tolerances tolerances inside side side edges, edges, hole hole sizes, sizes, thread thread sizes, sizes and and so so forth. forth. These These measures measures simplify simplify design design procedures procedures and and reduce reduce part part proliferation. proliferation. Design Design standardization standardization also also pays pays dividends dividends in manufacturmanufacturdrill sizes,and sizes, and fastener fastener ing distinct lathe tool nose ing by reducing reducing the the required required number number of of distinct lathe tool nose radii, radii drill sizes. reducing the amount of sizes. There There is also also a benefit benefit in terms terms of of reducing the amount of data data and and information information that that the the company company must must deal deal with. with. Fewer Fewer part part designs, designs design design attributes, attributes, tools, tools, fasteners, fasteners, and and so s< on other data n mean mean n fewer fewer and and simpler simpler design design documents, documents process process plans, plans, and and other other data records. records.
'
_

15.5.2 15.5.2

Survey Survey of Industry Industry Practice Practice

A to learn how industry A number number of surveys surveys have have been been conducted conducted to leam how industry implements implements cellular cellular man n.aii ufacturing [24], [24] [36], ufacturing companies represent [36], [38J. [38]. The The surveyed surveyed companies represent manufacturing manufacturing industries, industries, such such as machinery, machinery machine machine tools, tools, agricultural agricultural and and construction construction equipment, equipment medical medical equipequip, , ,

Sec. I Application Sec. 15.5 / Application Considerations Considerations in Group Group Technology Technology

441 441

TABLE 15.7 15.7 TABLE

Benefits of Cellular Cellular Manufacturing Manufacturing Reported Reported by Companies Companies in Survey Survey Benefits
Average Average Reason for for Installing Cells Reason Installing Manufacturing Manufacturing Cells Improvement ('Yo) Improvement (%)

Rank Rank

,
1
6

Reduce throughput time Reduce throughput time IManufacturing I Manufacturing lead lead time) time)
Beduce work-ln-process Reduce work-in-process

61 6'
48 48

2 2

3 3
4 4 5 5
7 7

8
9 9 10 10 11

Source: Wemmerlov and Johnson [381.

"

Improve Improve partand/or part and/or product product quality quality Reduce Reduce response response time time for customer customer orders orders Reduce rnove move d.stances distances Reduce Increase Increase manufacturing manufacturing flexibility flexibility Reduce unit unit costs costs Reduce Simplify Simplify production production planning planning and and control control Facilitate Facilitate employee employee involvement involvement Reduce Reduce setup setup times times Reduce Reduce finished finished goods goods inventory ini/entory

28 50
61 61

16 16

44 44

39 39

men t weapons merit. weapons systems. system;,, diesel dicseI engines. engines, and and piece piece parts. parts. Processes Processes grouped grouped into into cells cells in the the companies assembly, finishing, companies included included machining, machining, joining joining and and assembly, finishing, testing, testing, and and metal metal forming forming. Companies report their Companies in the the survey survey were were asked asked to to report their reasons reasons for establishing establishing machine machine cells implementing cellular cells and and the the benefits benefits they they enjoyed enjoyed from from implementing cellular manufacturing manufacturing in the the opoperations. Results Results are are listed Table 15.7. The The reasons listed in the the relative relative order order ofimof imerations. listed in Table reasons are are listed penance portance as indicated indicated by the the companies companies participating participating in the the survey. survey. We also also list the the average average percentage percentage improvement improvement reported reported by the the companies, companies, rounded rounded to to the the nearest nearest whole whole perpercentage point. Reasons 8, and centage point. Reasons 6, 6,8, and 9 are are difficult difficult to evaluate evaluate quantitatively, quantitatively and and no no percentpercentage age improvements improvements are listed listed in these these cases. cases. One One of of the the questions questions considered considered in the the 1989 survey survey [36] was: What What are are the approaches approaches The most most comcomused used by companies companies to lo form form machine machine ccus'' cells? The The results results are listed listed in Table Table 15.8. 15 8 The mon mon approach approach consisted consisted of of visually visually grouping grouping similar similar parts parts with with no no consideration consideration given given to to existing existing routing routing information information and and no no parts parts classification classification and and coding. coding. The The use use of a part-mapart-machine incidence matrix chine incidence matrix was was not not widely widely reported, reported perhaps perhaps because because the the formal formal algorithms algorithms for as rank order clustering (Section 15.6.1) were not widely for reducing reducing this this matrix, matrix such such rank order clustering (Section 15.6.1) were not widely known known at the time time of the the survey survey. Companies Companies also also reported reported costs costs associated associated with with implementing implementing cellular cellular manufacturing manufacturing j3o].Thc [36],The reponed reported cost cost categories categories are are listed listed in Table Table 15.9 together together with with the the number number of of comcompanies reporting reporting the the cost. cost. No panies No numerical numerical estimates estimates of of actual actual costs costs are are provided provided in the the report. report.
.

TABLE 15.8 15.a TABLE

Approaches to Cell Formation Formation Used Used in Industry Approaches Industry

Number of Number of Companies Companies

Approach to Cell Cell Formation Formation Approach to

Employing the Approach Employing the Approach 19 19 11 11

9 ~ 7

Text Reference Text Reference Section 15.1 15.1 Section Section 15.4.2 15 4 2 Section Section 15.3, 15 3 Section Section 15.6.1 Section
. . ,

inspection to to identify identify family family of Visual inspection similar parts parts similar machine concept concept Key machine part-machine incidence incidence matrix matrix Use of part-machine Other Other methods methods |e.g. ( _g., From-to Fromto diagrams, diagram", simple sorting sorting of routings) routings) simple
r

S(Jurce:Wemmerlovandliye,1361 Source: Wemmerlov and Hver (361

Chap. Group Technology Chap. 15 / Group Technology and and Cellular Cellular Manufacturing Manufacturing TABLE TABLE 15.9 Costs Costs of of Introducing Introducing Cellular Cellular Manufacturing Manufacturing Reported Reported by Companies Companies
in Survey Survey Number of Cc Number erofCompant of Companies

Cost
1 1. 2 2. 3 3. 4 4. 5 5. 6 6. 7 7. 8 8. 9 9.
. . . . .

Reporting Reporting

Relocation and and installation installation of machines machines Relocation Feasibility )n, and and related related costs costs Feasibility studies, studies, planning planning and and design, design, New equipment uipment equipment and and duplication duplicatiori of equipment equi| Training Training New tooling tooling and and fixtures fixtures Programmable and software Programmable controllers, controllers, computers, computers, and software Material handtinq Material handling equiprnent equipment Lost production production time time during (luring installation installation Higher Higher operator operator wages wages

16 8 6 6 5 4 2 2 1 1

Source-Wem.-nerlovandHyar[36] lerlovand Hyer [361.

Topping equipment relocation Topping the the list wa.s was the the expense expense of of equipment relocation and and installation. installation. Most Most of of the (he companies companies responding responding tu to the the survey survey had had implemented implemented cellular cellular manufactunng manufacturing by by moving moving equipment equipment in the the factory factory rather rather than than hy by installing installing new new equipment equipment to to form form the the cell. cell.

15.6

QUANTITATIVE ANALYSIS ANALYSIS IN CELLULAR MANUFACTURING MANUFACTURING QUANTITATIVE IN CELLULAR

A number number of quantitative quantitative techniques techniques have have been been developed developed to to deal deal with with problem problem areas areas in this sectioi group group technology technology and and cellular cellular manufacturing. manufacturing. this section, section, we consider consider two two problem problem j In this areas: s: (1)) grouping families and grouping parts parts and and machines machines into into families, ft and (2) (2) arranging arranging machines machines in a GT GT and several several of of the the cell. The first problem area cell. The first problem area has has been been and and still still is an active active research research area, area and more more significant significant research research publications publications are are listed listed in our our references references [2}, [2] [3}, [3], [II}, [11], [12], [26}, [26], [27}. [27]. The The technique technique we describe describe in the the current current section section for for salving solving the the part part and and machine machine groupgrouping The second ing problem problem is rank rank orderciustering order clustering [26J. [26].The second problem problem area area has has also also been been the the subsubject ject of of research, research, and and several several reports reports are are listed listed in the the references references [1], [6], [8]. [8], [17). [17]. In Section Section 15.6.2. describe two introduced by 15.6.2. we describe two heuristic heuristic approaches approaches introduced by Hollier Hollier II7]. [17]
.

15.6.1 15.6.1

Grouping Grouping Parts Parts and and Machines Machines by Rank Rank Order Order Clustering Clustering

The machines in The problem problem addressed addressed here here is to to determine determine how how machines in an existing existing plant plant should should be be grouped grouped into into machine machine cells. The The problem problem is the the same same whether whether the the cells ceils are are virtual virtual or or forformal (Section 15.5.1 ).It mal (Section 15.5.1). It is is basically basically the the problem problem of of identifying identifying part part families. families By By identifyidentifying part families the ing part families, machines required in the cell to produce the part family can be the machines required in the cell to produce the part family can be properly selected. As properly selected. As previously previously discussed, discussed, the the three three basic basic methods methods to to identify identify part part famfamilies are are (1) (1) visual visual inspection, inspection (2) ilies (2) parts parts classification classification and and coding, coding, and and (3) (3) production production flow flow analysis. analysis. The first proposed The rank rank order order clustering clustering technique. technique first proposed by by King King [26J, [26] is is specifically specifically apapplicable efficient and plicable in in production production flow flow analysis. analysis. It It is is an an efficient and easy-to-use easy-to-use algorithm algorithm for for groupgrouping celts. In ing machines machines into into celts. In a starting starting part-machine part-machine incidence incidence matrix matrix that that might might be be compiled compiled to to document document the the part part ruutings njutings in in a a machine machine shop shop (or {or other other job job shop), shop), the the occupied occupied locations locations in are organized fashion. Rank in the the matrix matrix are organized in in a a seemingly seemingly random random fashion Rank order order clustering clustering works works
.

Sec. 15.6 I Quantitative Analysis Analysis in Cellular Cellular Manufacturing Manufacturing Sec. / Quantitative

443

bv reducing the the part-machine part-machine incidence incidence matrix set of blocks that repreby reducing matrix to a a set of diagonalized diagonalized blocks that represent part part families families and and associated associated madiiut' machine groups. groups. Starling Starting with with the the initial initial part-machine part-machine in insent
-

cidence matr matrix. the algorithm algorithm consist, of the the following steps: cidence ix, the consists of following steps:
1 1.
.

s)fromleft In each each row row of of the the malrix.read matrix. read the the series series of Is ls andO and G's entries = = O D's) from left s (blank (blank entries fight as a binary binary number. number. Rank Rank the 01 del uf decreasing value. case of of a to right the rows rows in oidci of decicasing value. In case
'

"

tie, rank rank the the rows rows in the the same same order order as they they appear the current current matrix. matrix tie, appear in the
2 2.
.

Numbering from top to to bottom, bottom, is ihe the current current order of rows same as the rank order Numbering from top order of rows the same the rank order determined in the the previous previous step? step? If to step step 7, no, go to to the the following following step. step. determined If yes, go to 7. If no, Reorder the rows in the the part-niachine part-machine incidence matrix by listing them decreasing Reorder the rows incidence matrix listing ther a in decreasing rank order, order, starting from the the top. top rank starting from In each each column column ot tbe matrix. read the series of of 1I 's and (blank entries entries = (I's) (j's) from from ot the matrix, read the series and O's (blank top to bottom as a binary binary number. number. Rank Rank the the columns columns in order order of decreasing value. value, In top to bottom of decreasing case of of a tie. rank the the same same order order as they they appear appear in the the current current matrix. matrix. case tie, rank the columns columns in the

3 3,
.

4 4.
.

5 5. Numbering Numbering Irom left to right, right, is the the current current order order of columns columns the the same same as the the rank rank Irom left
.

order determined determined in the the previous previous step? step? If yes, yes. go to step If no. no.go to the the following following step. step. order step 7. If go to
6 6. Reorder the columns columns in the the part-machine, part-machine incidence matrix matrix by listing li~ling them them in dedeReorder the incidence
.

creasing rank order, starting starting with with the left column. column. Go to step creasing rank order, the left Go to step I. 1. Stop 7 Stop. For readers readers unaccustomed unaccustomed to evaluating evaluating binary 1 and and 4, it might might be helpFor binary numbers numbers in steps steps 1 be helpto convert convert each each binary value into into its decimal decimal equivalent (e.g., the entries in the the first first row row ful to binary value equivalent (e.g., the entries of the the matrix matrix in Table Table 15.4 are are read read as 100100010). 100100(10). This converted into into ils its decimal decimal equivof This is converted equivb + 1x2 5 + 0x2' alent + Ox2' Oxl1 + Ox2 O.rl" 1x2s = alent as as follows: follows: U-28 lx28 + Ox24 + 0x23 Ox23 + ()x2z Ox22 + 1x2' Ix2] + 0x2 Ox2 = 256 + 32 + +2 = should be mentioned that that decimal conversion becomes becomes impraciiimpracti256 = 290. It should be mentioned decimal conversion for the the large large numbers numbers of parts found found in practice, practice, and comparison of of the the binary binary numbers numbers cal for of parts and comparison preferred is preferred. EXAMPLE 15.3 Rank Rank Order Order Clusier Cfuseering EXAMPLE ing Technique Technique Apply the rank rank order order clusiering clustering technique technique to the the part-machine part-machine incidence incidence mamaApply ihe trix in Table 15.4. trixinTable 15.4 Solution: Step I consists consists ol 01 reading reading the series of of 1 1 's and 0"s D's in each each row row as a binary binary numnumSolution: Step 1 the series ber. done this this in Table Table 15.IO(a). converting the the binary binary value each ber. We have have done 15.10(a) converting value for for each row equivalent. The values are are then then rank ordered in the the far far rightrightrow to to its decimal decimal equivalent. I he values rank ordered hand step 2 2. we see see that that the the row row order order is different different from from the starting hand column. column. In step the starting matrix. reorder the the rows rows in step step 3 3. In step step 4, we read read the the series series of matrix. We therefore therefore reorder of I's column from from top bottom as a binary binary number (again we have have Ts and and D's O's in each each column top to bottom number (again and the of converted the decirnalcquivajenr], the columns columns are are ranked ranked in order order of converted to to the decimal equivalent) and decreasing shown in Table Table 15.10(b). 15.10(b).lnIn step 5, we see that the column decreasing value, value as shown step see that the column order from the the preceding matrix. Proceeding Proceeding from from step step 6 back back to order is different different from preceding matrix to steps reordering of the columns columns provides provides a row row order order that that steps 1 1 and and 2, we see that that a reordering of (he is in descending value. and and the algorithm is concluded concluded (step (step 7). The The final final solusotudescending value the algorithm tion is shown shown in Table 15.10(c) A riou Table 15.10(c), A close close compa comparison of this this solution solution with with Table Table rison of 15,5 they are the same carne part-machine part-machine groupings, 15.5 reveals reveals that that they are the groupings
, ,
.

444

Chap. Chap. 15 15

I / Group Group Technology Technology and and Cellular Cellular Manufacturing Manufacturing

TABLE
15.3 15.3

TABLE 15.10{a} 15.10{al

Binary Values

First Iteration

First Iteration {Step (Step 1) 1) in in the the Rank Rank Order Order Clustering Clustering Technique Technique Applied Applied to to Example Example

2"

a
Parts

"

"

"

Decimal Decimal

Machines

Equivalent Equivalent
290 290

Rank Rank
1 7

17 81 13. 258 65 140

5
4 2

6
3

TABLE TABLE 15.101bJ 15.10(bl

Second the Rank Second Iteration Iteration (Steps (Steps 3 and and 4) 4) in the Rank Order Order Clustering Clustering Technique Technique Applied Applied

to Example Example 15.3 15.3 to

Parts Machines

Binary Binary Values Value

2" a

2= a
, a
4

2J a

2U a
Decimal Decimal Equivalent Equivalent

"

96

64

24

16

96

Rank Rank

Sac. " Quantitative Ouantltetive Analysis Cellular Manufacturing Sec. 15.6 15.6 / Analysis in Cellular Manufacturing

445

TABLE 15.10(c) TABLE 1S.10Ic)

Solution of 15.3 Solution of Example Example 15.3

Parts

Machines

,
1

1 1

1 1

,
1

, ,

, ,

machines into three In the the example example problem problem, it was was possible possible to divide divide the the parts parts and and machines into three In mutually exclusive part-machine part-machine groups. This This represents represents the the ideal ideal case case because the part mutually exclusive groups. id* because the part families and associated machine cells cells are are completely completely segregated. However, it is not not ununfamilies and associated machine letely segregated. segregate However it common for for there there to to be be an overlap overlap in processing precessing requirements common requirements between between machine machine groups groups, That is. is, a given given part part type type needs needs to to be be processed processed by than one one machine machine group. Let us Thai by more more than group. Let illustrate Ihis this case case and and how how the the rank rank order order cluster clustering with il it in the the followfollowillustrate ing technique technique deals deals with ingexampJe. ing example.
, ,

EXAMPLE 15.4 EXAMPLE

Overlapping Machine Meehjne RequiremenfS Overlapping Requirements

Consider 15.ll.This the same Consider the the part-machine part-machine incidence incidence matrix matrix in Table Table 15.11. This is the same as the the
original part-machine part-machine incidence incidence matrix matrix in Table Table 15.4 except that that part part B requires requires original 15.4 except TABLE 15.11 15.1' TABLE
Part-Machine Incidenca Matrix for for Example Part-Machine Incidence Matrix Example 15.4 15.4

Parts Parts
Machines

5 6
7

446

Chap. 15 15 / / Group Technology and Cellular Cellular Manufacturing Chap. Group Teclinology and Manufacturing

processing on machines machines 1.4, and and 7 (1 is the additional machine) machine) and and partD now jrocessing on the additional part D now he requires processing processing on on machines machines 1 and 4 (4 is the the additional machine). Use Use t the requires 1 and additional machine). rank order parts and machine into into groups. groups. rank order clustering clustering technique technique to arrange arrange parts and machine Solution: The rank rank order order clustering clustering technique two iterations, iterations, Solution: The technique converges converges to a solution solution in in two shown in Tables Tables 15.12(a) 15.12(a) and and 15.l2(b), the final shown in shown 15.12(b), with the final solution solution shown in Table1.'l.12(c). TablelS. 12(c). First Iteration Iteration of Rank Rank Order Order Clustering Clustering Applied to Example 15.4 First of Applied to Example 15.4
2" 2"

TABLE IS.12{a) 15.12Ia) TABLE Binary Values Values Binary

2)

6 2s 2

2"

2' Parts

23 2'

2'

2'

2'
Decimal
:qu(Valert Equivalent

Machines
1 2 3

Ran(

418 17 B1 '68
7 5 3
2

258
65 65

6 7

6
4

140
Second Iteration of Rank Order Order Clustering to Example Example 15.4 Second Iteration of Rank Clustering Applied Applied to 15.4

TABLE 15.12(b) 15.12(b) TABLE

Parts Parts
Machines Machines A ABCDEHGHI

Binary Binary Values Values

2 2"

5
4 7

I;
1 1

-_

__.

1 1 1 1 1 1 1

26 2' 2' 2' 23 2'

1 1

3
S 2

2' 2' 21 2'

2 2'

I
96 96

Decimal Decimal luivalent Eqi EQuivalent

Rank

68

24

96

Sec.15.6 Analysis in Cellular Sec. 15.6 / Quantitative Quanlitaiive Analysis Cellular Manufacturing Manufacturing TABLE15.12lcl TABLE 15.12(c) Solution of Example 15.4 15.4
Parts

447 447

"-1'
5
7

-,

I~

3 6 2

Parts Parts B and and D could could be be included included in either either of of two two machine machine groups. groups. Our Our solution solution includes includes them them in machine machine group group (-1.7); (-1, 7); however, hnwever, they :hcy must must also also be proee~s,,<J processed ill in machine machir.e group group i!. il. 5) 5).

King Bl and Dj (parts King [26] refers refers to to the the matrix matm elements elements Bl and Dl (parts Band B and D processed processed on man chine elemems, chine I) in Table Table 15.l2(c) 15.12(c) as exceptional exceptional elements. mts. He He recommends recommends that that they they each each he be reas zeros placed with an asterisk asterisk (*) and and treated treated a is when when applying applying the the rank rank order order clustering clustering technique. The effect our example technique. The effeci of' of this this approach approach in our example problem problem would would be to to organize organize the the machines ichincs exactly etaclly as as we we have have done done in our our final final solution solution in Table Table 15.12(c).Anotherway 15.12(c}. Another way of of dealing dealing with with the the overlap overlap h is simply simply to duplicate duplicate the the machine machine that thai is used used hy by more more than than one o part part family. family. In In Example Example 15.4, this this would would mean mean that that two two machines machines of of type type 1 1 would would be used used in the the two two censTbe cells. The result result of this this duplication duplication is shown shown in in the the matrix matrix ofJable of'fable 15.13.where 15.13. where the two two machines machines are are identified identified as l la and j lb. Of course. course there the a and b. Of there may may be be economic economic considerconsiderations alkms that that would would inhibit inhibit the the machine machine redundancy. redundancy. Other attributed to to Burbidge Burbidge Other approaches approaches to to the the problem problem of of overlapping overlapping machines, machines attributed : pn. [26J, [26], include: include: (1) change change the the routing routing so so that that all processing processing can can be accomplished accomplished in the the pnmary mary machine machine group. group. (2) (2) redesign redesign the the part part to to eliminate eliminate the the processing processing requirement requirement outside out the the primary primary machine machine group, group, and and (3) purchase purchase the the part part from from an an outside outside supplier. supplier
' ~*

15.6.2 15.6.2

Arranging Cell Arranging Machines Machines in 8 a GT Cell

After en identified After part-machine part-machine groupings groupings have have he been identified hy hy rank rank order order clustering clustering or or other other method. machines into method, the the next next problem problem is to to organize organize the the machines into the the most most logical logical arrangement. arrangement Both methods Let describe two methods suggested [17].2 2 Both methods Let us describe two simple simple yet yet effective effective methods suggested by by Hollier Hollier [17] use are intended to arrange the use data data contained contained in in From-To From-To charts charts (Section (Section 10.6.1) 10 6 1 j and and are intended to arrange the mamachines chines in an order order that that maximizes maximizes the the proportion proportior o of wj in-sequence in-sequence moves moves within within the the cell cell
,
. .

'

..

H0ll,el r

IHollicr] inlrod

six heuristic approaches to

which we dcs nbc ih: firs; [wo

ing the machine arrangement problem

of

448 TABLE 15.13 15.13 TABLE

I Group Technology Technclcgv and Cellular Cellular Manufacturing Manufacturing Chap. 15 /

Solution to Example Example 15.4 Using Using Duplicate Duplicate Machines of Type Tvpe 1 1 {Shown Solution to 15.4 Machines of {Shown

as Machines 1a 1b in the Matrix} as Machines ta and and 1b in the Matrix} Parts Parts
Machines

la

"

1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

lb

1 1

Hollier Method rst method the sums of fl ow "From" "From" and and "To" Hollier Method 1. 1. The The fi first method uses uses the sums of flow "To" each each machine method can be outlined machine in the the cell.The cell. The method can be outlined as follows: follows:
1 L
.

Df!1'elopthe chartfrom The data data contained contained in the the chart chart Develop the From-To From-To chart from part pan routing routing data. data. The
indicates numbers of part part moves moves between between the machines (or (or workstations) the cell. indicates numbers of the machines workstations) in the
Moves not included Moves into into and and out out of of the the cell cell are are not included in in the the chart. chart.

2 2. Determine Delermine the the "From" "From" and lUId "To" sums for for each eQch machine. accomplished by "To" sums machine. This This is accomplished
.

summing all all of of the the "From" trips and and "To" "To" tr trips for each each machine machine (oroperation).The (or operation). The summing From" trips ips for
"

"

"From" sum for for a machine machine is determined determined by adding adding the the entries entries in corresponding From" sum in the the corresponding
"

row, and the row, and the "To "To" sum sum is found found by adding adding the the entries in the the corresponding column. entries in corresponding column.
3

3. Assign machines to the cell based hosed on minimum "To" sums. The The machine machine Assign machines minimum "From" "From" or "To"
.

having the the smallest smallest sum sum is selected. selected. If the the minimum sum, then then the the mamahaving minimum value value is a "To" "To" sum chine is placed placed at at the the beginning of the the sequence. sequence. If If the the minimum minimum value value is a "From" "From" chine beginning of sum, then then the machine is placed placed at at the the end end of of the TIe breaker rules: sum, the machine the sequence. sequence. Tie breaker rules:
,

(a) minimum "To" minimum "From" then the (a) If If a tie tie occurs occurs between between minimum "To" sums sums or or minimum "From" sums, sums, then the machine with with the ratio is selected. machine the minimum minimum "From/To" "From/To" ratio selected. (b) and "From" "From" sums sums are equal for for a selected machine,it it is passed passed over over (b) If If both both "To" "To" and are equal selected machine, and the machine with the next lowest sum is selected. and the machine with the next lowest sum is selected. (c) If a minimum sum is equal minimum "From" "From" sum, sum, then machines minimum "To" "To" sum equal to a minimum then both both machines are selected selected and and placed placed at at the the beginning and end of the sequence, respectively. respectively. are beginning and end of the sequence 4 Rejrmnat Reformat the From-To From-To chart. After each has been 4. chan. After each machine machine has been selected, selected, restructure restructure the the From-To the row row and and column column corresponding corresponding to 10 the selected mamaFrom-To chart chart by eliminating eliminating the the selected chine the "From" "From" and and 'To" "To" sums. sums. Repeat Repeat steps steps 3 and and 4 until until all all machine and and recalculate recalculate the machines assigned. chines have have been been assigned.
,
.

Sec. 15.6 15.6 / / Quantitative Quantitative Analysis in Cellular Cellular Manufacturing Sec. Analysis in Manufacturing

449 449

EXAMPLE 1S.S 15.5 Group Group Technology Machine Sequence Sequence using using HoDier Method 1 EXAMPLE Technology Machine Hollier Method
3 and Suppose that that four four machines, machines. 1 I, 2 2.3, and 4 have have been been identified identified as belonging belonging in Suppose OT machine machine cell. cell. An An analysis analysis of of 50 parts parts processed processed on on these a GT these machines machines has been summarized summarized in the 14. Additional Additional information been the From-To From-To chart chart of of Table Table 15 15.14. information that 50 '50 parts the machine machine grouping grouping at machine 3,20 leave after after prois that parts enter enter the machine 3 20 parts parts leave processing at machine machine 1, and parts leave leave af after machine 4. Determine logical mamacessing and 30 parts ter machine Determine a logical chine arrangement arrangement using using Hollier Hollier Method chine Method 1. 1.
,
.

Solution: Summing the From From trips trips and trips each machine machine yields yields the "From" and and Solution: Summing the and To t rips for for each the "From"
"

"To" sums in Table The minimum minimum sum value is the "To" sum for mamaTo" sums Table 15.15(a). 15.15(a). The sum value the "To" sum for chine 3. Machine Machine 3 is therefore therefore placed placed at at the the beginning beginning of of the the sequence sequence. ElimElimchine inating the row row and and column column corresponding corresponding to machine yields the the revised revised inating the lo machine 3 yields From-To chart chart in Table Table 15.15(b). 15.15(b). The The minimum minimum sum sum in this chart is the the "To" "To" From-To this chart
.

TABLE 15.14 15.14 TABLE

From-To Chart for for Example 15.5 From-To Chart Example 15.5

To: To: From: From: 1 1

12 0 5

3 0

4 25

2 3
4
TABLE 15.151a) 15.1518) TABLE

30 10 10
10 10

0 40
0

0 0
0

"
15 0
0 First First

From and and To To Sums Sums for for Example Example 15.5: From 15 5:
.

Iteration Iteration

To: To: From: From: 1 1 2 3

4
"

1 0 0 30 '0

2 5 5 0 0 40

3 3 0 0 0 0

4 4 25

"From" Sums "Fromwsum. 30 '0

"
15 15 0 0
0 0

45
50 50
10 10

10 10
50

0 0
0 0

0 45

wTo"'sums To" sums

TABLE TABLE 15.15(b) 15.151bJ

40 40

135 135

5: From and To To Sums for Example Example 15 From and Sums for 15.5:
.

Second Iteration with Machine 3 Removed Removed Second Iteration with Machine 3
To: To: 1 2 4 "From" "'From'" Sums Sums

From: From:

1 1 2
4

0 30
10 40 40

5 0
0 5

25 25 15 15
0 40 40

30 ae 45 45
10 '0

'0

"

NTowsums To'sums

Chap, 15 I Technology and Cellular Manufacturing Chap. / Group Group Technology and Cellular Manufacturing

TABLE TABLE 15.15(c) 15.15(cl

From and and To To Sums for Example Example 15.5: 15.5: Third From Sums for Third Iteration with Machine 2 Removed Iteration with Machine Removed
1
0 10 10

To: To:
FromFrom' J 4

4
25 0 0

"From" MFrom" Sums Sums

25 10 10

MTo" sums

10

tu

25

sum to machine machine 2. which which is placed at the the front front of at the the sequence, sequence, n corresponding corresponding to placed at immediately following machine machine 3. Eliminating machine 2 produces produces the revised immediately following Eliminating machine the revised From-To chart chart in Table minimum sum From-To Tahle 15.15(c). 15.15(c). The The minimum sum in this this chart chart is the the "To" "To" sum for placed after after machine and finally machine 4 sum for machine machine 1. I. Machine Machine 1 I is placed machine 2 and finally machine placed at the the end end of of the the sequence. sequence. Thus, the resulting resulting machme machine sequence sequence is is placed Thus, the
3 -> 2 1 -v 4 3--->2--->1--->4

Hollier Method Method 2. This This approach approach is based based on the use of From/Ib ratios ratios formed Hollier the use of From/To formed by summing the the total total flow flow from from and and to each each machine the cell. cell. The The method method can can be he reduced reduced summing machine in the to three three steps: steps: to
1 1.
.

Develop From-To eAaW.This chart. This is the Hollier Method Method 1. Develop the the From-To the same same step step as in Hollier Determine the From/To From/To ratio for each machine. This This is i~ accomplished summing Determine the ratio for each machine. accomplished by summing The "From" up all of the the "From" "From"trips "To" trips trips for each machine (or operation). The "From" up trips and and "To" each machine (or operation) sum for for a machine machine is determined determined by adding adding the the entries entries in the the corresponding corresponding row row, and and sum the "To" "To" sum detcnnined by adding adding the the entries entries in the the corresponding corresponding column. For the sum is determined column For each each machine machine, the the From/To ratio is calculated taking the the "From" "From" sum maFrom/To ratio calculated by taking sum for for each each machine and dividing dividing by the the respective chine and respective "To" "To" sum. sum
.

2 2.
.

3 3.
.

Arrunge machines in in order order of of decreasing decreasing From/To From/To ratio. ratio. Machines Machines with with a II high high Arrange machines From/To ratio ratio distribute work to many machines in the but receive receive work work from few From/To distribute work many machines the cell but from few machines with From/To ratio machines. Conversely Conversely, machines with a low low Fromffo ratio receive receive more more work work than than machines. they distribute. they distribute. Therefore Therefore, machines machines are are arranged arranged in order order of of descending descending From/To Prom/Io ratio. That is, machines with high ratios are placed at the beginning of of the work flow, ratio.That machines with high ratios are placed the beginning the work flow and machines machine, with with low ratios ratios are are placed placed at the the end end of the work work flow. in case case of of a tie tie, and of the flow In the machine machine with with the the higher higher "From" "From" value value is placed placed ahead ahead of of the the machine with a the machine with lower lower value. value
,

EXAMPLE 15.6 Group Group Technology Technology Machine Machine Sequence using Hollier EXAMPLE Sequence using Hollier Me.hod Method 2 Solve Example Example 15.5 using Hollier Method Method 2 2. Solve using Hollier
,
.

Solution: Table 15.15(a) Solution: Table 15.15(a), containing containing the the "From" "From" and and "To" sums, is repeated Table 15.16, "To" sums, repeated in Table 15.16 along along with with the the From/To From/To ratios ratios given given in the the last last column column on on the the ri right. Arranging ght. Arranging
,

machines in the machines in III order order of of descending descending From/To Prom/To ratio ratio, the the machines in the the cell cell the machines should he sequenced sequenced as follows: follows' should be
,

3--->2~1 __ 4 4 3 2 - 1 -

Sec. / Quantitative Analysis in Cellular Manufacturing Manufacturing Sec. 15.6 15.6 I Quantitative Anetvse in Cellular
TABLE 15.16 TA.BLE 15.16 From-To Sums and and From/Jo Ratios for Example 15.6 ?5.6 From-To Sums FromfTo Ratios for Example
To. To:
from: From' I 1 2
3 4 To"sums HTo" sums
"

451

451

12
0 5 0

3
0 0
0 0 0

4
25 15
0 0

MFrom~ From" Sums Sums

"

From/To Ratio Ratio From/To 0.60

30
45

30 10 10 50

1.0
oc 0.25

40
0 45 45

50 10 135

40

This This is the the same same solution solution provided provided by Hollier Hollier Method Method 1. 1.

\()

15

~Om ~

O"'25

2 5

4 10

300ul 200ul

figure machine cell cell in Figure 15.14 15.14 Flow Flow diagram diagram for for machine in Examples Examples 15.5 lind and out of of the included. 15.6. Flow Flow of of parts parts into into lind and out the cells cells has has also also been been included.
such as the the flow diadiaIt It is helpful helpful to to use use one one of of the the available available graphical graphical techniques, techniques such gram work flow The flow gram (Section (Section 10.6.1), 10.6.1), to to conceptualize conceptualize the the work flow in in the the cell. cell.The flow diagram diagram for the ihc machine machine arrangement arrangement in in Examples Examples 15.5 and and 15.6 is presented presented in Figure Figure 15,14. 15.(4. The The work work flow is mostly fluw mostly in-line; in-line; however, however, there there is some some back back fl ow or of parts parts that that must must be be considered considered in the the design design of of any any material material handling handling system system that that might might be be used used in the the ceH. cell. A A powered powered convey conveyor or would would be be appropriate appropriate for for the the forward forward flow flow between between machines. machines, with with manual manual handling handling for the the back back flow. for For For our our example example data data in Table Table 1'1.14, 15.14 Hollier Hollier Methods Methods 1 and and 2 provide provide the the same same solution. This is not The relative methods depends lution.This not always always the the case. case.The relative performance performance of of the the two two methods depends on problem. In some problems.Method other on the the given givenproblem.lnsome problems,Method J1 will outperform outperform Method Method 2.and 2.and in mother problems problems the the opposite opposite will will happen. happen. In many many problems, problem the the twomethods two methods yield yield identical identical solutions, lutions, as in Examples Examples 15.5 15,5 and and 15.0. 15.6. Hollier Hollier presents presents a comparison comparison of of these these and and his other other proposed proposed methods methods with with a variety variety of of problems problems in [17J. [17]. Two performance performance measures measures can can be defined defined to compare compare solutions solutions to to the the machine machine sesequencing quencing problem: problem: (1) (1) percentage percentage of of in-sequence in-sequence moves moves and and (2) (2) percentage percentage of of backtrackbacktracking ing moves. moves. The The percentage percentage of of in-sequence in-sequence moves is computed computed by by adding adding all of of the the values values representing by the the total representing in-sequence in-sequence moves moves and and dividing dividing by total number number of of moves. moves The The percentpercentage age of of backtracking backtracking moves moves is determined determined by summing summing all of of the the values values representing representing backbacktracking tracking moves moves and and dividing dividing by the the total total number number of moves. moves
, ,
.

EXAMPLE EXAMPLE 15.7

Perfonnance in Performance Measures Measures for for Alternative Alternative Machine Machine Sequence Sequences in II a GT C.T c{"\1 cell

Compute Compute (a) (a) the the percentage percentage of of in-sequence in-sequence moves moves and and (b) (b) the the percentage percentage of of backtracking solution in Examples and 15.0. 15.6. backtracking moves moves for for the the solution Examples 15.5 15 5 and
.

452

Chap. 15 / / Group Technology and Cellular Cellular Manufacturing Chap. 15 Group Technology and Manufacturing

Solution: From Figure Figure 15.14, the the number number of in-sequence in-sequence moves = 40 + 30 + 25 = = 95, Solution: From moves = number of hacktracktng moves = 5 + 10 = 15. 15. The number of and the number backtracking moves The total total number moves = 135 (totaling (totaling either either the sums or or the the "To" "To" sums), Thus, sums). Thus, moves the "From' . From" sums
'

(a) Percentage Percentage of of in-sequence in-sequence rnoves > 95/135 = 0.704 0.704 = = 70.4% 70.4% (a) moves = 95/135 = Percentage of backtracking (b) Percentage backtracking moves - 15/135 = = 0.111 0.111 ~ = 11.1%

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1983 pp 55-78. [24] HYER,N [24] Hyer, N. L.. and U.WEMMFRLOV, U.Wemmfrlov, "Group "Group Technology in the U.S.Manufacturing U.S. Manufacluring Industry:A IniiustryiA Surveyof Vol.27, 1989,pp International lournal Journal of of ProducrionResearch. Producrion Research.Vo[.21,1989, pp 1287-1304. 1287-1304. vey of Current Practices," Practices, tmernationsl
"

[25] IRANI,S .. T [25] Irani, SA A., T M. CAVALlfR,and CAVALI .and P.H.COHEl\,"Virtual P.H.Cohen,"Virtual ManufacturingCells:Exploiting Manufacturing Cells. Exploiting LayOUiDesign Internalional Journal Journal of of out Design and lntercell Intercell Flows for the Machine Machine Sharing Sharing Problem," Problem, lntemationai Production 1993.pp791-810 Production Research,VoI.31, Research.Vcl 31.1993.pp 791-810. [261 [26] KIN(j, Kino, J. J. R., -wecntne-componem " Machine-Component Grouping Grouping in r-rooucuon Production now How Analysis: an Approach Approach Using a Rank International Journal of of Production Production Research, Vol. Vol. 18, 18, Rank Order Order Clustering Clustering Algorithm," Algorithm, International 1980.pp213-222 1980, pp 213-222. [27] EXGT-S: A Knowledge Technology," Imemationai lour[27] KUSIAK,A., Kusiak, A., " "EXGT-S: Knowledge Based System for Group GroupTf echnologyr/niernntionf liJournat of Production 26, 1988,pp 1353-1367 nalof Produaion Research, Vol. Vol.26,1988,pp 1353-1367. [28] [28| LYNCH, Lynch, M., M., CrompurerNumerical Computer Numerical Control Control for for Machining, McGraw-Hill, McGraw-Hill, Inc" Inc., New York, 1992 1992.
" "

[2Q1 Industrial [29] Moxoex Monden, Y, Y., Toyota Production Production System, Industr ial Engineering Engineering and Mnnllg",ment Management Press. Press, Insr. Inst. Industrial Industrial Engineers. Engineers, Norcross, Norcross Georgia, Georgia, 1983 1983. [30J , R. [30] MOODIE, Moodje, C C, R. lJ7-S0Y,and IJzsoy, and Y Y. YIH,Manufacturing Ym, Manufacturing Cell.s:A Cells:A Systems Systems Engineering Engineering View, Taylor 1995. & & Francis Ltd" Ltd., London, London, U.K., U.K. 1995.
,
,

[31] [31] OPITZ,H__ Opitz, H., A A Classification Classification System System to De.trribe Describe workpieces, Workpieces, Pergamon Pergamon Press, Oxford, Oxford, England, ig o. land,1970 [32J and H. P.WIE'IDAHL, Group Technology and Manufacturing [32] OPITZ,H., Opir/,,H.,and P. Wiendahl, " "Group Manufacturing Systems for Medium Quantity laumai of Quantity Production." lruemanonal IntemanonaUoumai of Production Research. Research, Vol.9,No.l, Vol. 9,No.l, 1971.pp 1971, pp 181-203 181-203. [33] .,and ellular Manufacturing [33] SINGH, Singh, N N., and D. D. RAJAMA:-I, Rajamani, C Cellular Manufacturing Systems: Design. Design, Planning, and Control. 19%. Chapman Chapman & & Hall, London, London 1996.
,

[34] [34] SNEAD, Snead, C C.. S., S., Group Technology: Technology: Foundation Foundation for for Competitive Competitive Manufacturing, Manufacturing, Van Nostrand Nostrand Reinhold New York, 1989 1989. Reinhold,
,

[35] [35] VAKHARIA. Vakharia, A. 1.,and J., and H H.. .\1. M. Selim, "Group "Group Technology," Handbook Handbook of of Design, Manufacturing Manufacluring and Automation, (Editors),John Inc., New York, 1992, Automation, R. R, C C. Dorf and and A. Kusiak (Editors) John Wiley & Sons, Sons,Inc.,New York,;992, pp435--460. pp 435-160.
,

[36] Cellular Manufacturing Manufacturing in U.S.Industry:A [36] WEMMEkLOV, Wemmerlov, 0., U., and N. N. L. L. HYER, Hyer, " "Cellular U.S. Industry: A Survey of Users," International 27 1989 pp 1511-1530 Imernatimal Journal of of Production Production Resean'h, Researeh Volume 27,1989, 1511-1530.
. , ,

[37J OV,0.. [37] WEM.\1t.Rl WEMMtaiov, U, and and N. L. L. HYER."Group Hyer. "Group Technology," Handbook Handbook of of Industrial Industrial Engineering, G Salvendy (Editor),John G. (Editor), John Wiley & Sons, Inc., New York, York 1992,pp 1992, pp 464-488. 464- 88.
.

138] J. JOHNSON, 138] WEMMERI.OV, Wemmerlov, LT.. U., ~nd and D. D.J. Johnson, "Cellular "Cellular Manufacturtng Manufacturing at ee 46 User Plants: ImplementaImplementanon tion Experiences Experiences and and Performance Performance Improvements," Improvements International International Journal Journal of of Production Production Research Volume 35, search.Volurne 19l17,pp 35,1997, pp 29--49. 29-49.
" ,
,

[39J [39] WILD.R.. Wild. R.. Mas,1Production Wart Production Management, Management, John Wiley & & Sons Ltd., London, London 1972,Chapter 1972, Chapter 8.
,

454 454

Chap.

15 I Chap. 15 / Group Group Technology Tecfinology and and Cellular Cellular Manufacturing Manufacturing

PROBLEMS PROBLEMS

Parts Parts Classification Classification and and Coding Coding

1S.1 Develop the form ttiJe (first five digits) in Hit Opitz System for Die part illustrated in Fig15.1
ure P15.1.

ireP15.1 Part for for Problem Problem 15.1. Figure PIS.! Part lemions are are in millimeters. miilttnetcrs. Dimt Dimensions

15.2

Develop in the Opitz Develop the me form form code (first five five digits) in Opitf System System for the part part illustrated illustrated in Figure P15 2 ureP15.2
. .

ire P15.2 P15.2 Part Part for for Problem Problem 15.2. Figure Figui lenstons are Dimt Dimensions are in millimeters. millimeters.

15.3 1SJ

Develop the th.e form code (first five Develop five digits) in in the Opitz OpiU System System for the part part illustrated illustrated in Figure P15.3. ur"P15,3

SpurgellT 36.0piwhdiamereT

I
r

P=L

(h(llh~nd~)

43.0 -.

Figure P1SJ P15.3 Part Figure Part for for Problem Problem 15.3. Dimensions Dimensions are are in millimeters. millimeters.

Problems Order Clustering Clustering Rank Order

15.4 15.4

455

Apply [lie rank order clustering technique lo the part-machine incidence matrix in the follovmig tahlc to identify logical pari families and machine groups. Parts are identified by let:

rs, and machines are

identified numerically
A A 1 1

Parts Pans

Machines
1

,----1

2 3

4
5

1
1

155

AppK the rank order clustering technique to the part-machine incidence matrix in the following table to identify logical pari families and machine groups. Parts are identified by letA~' P~P,:"~ ters. and machines are identified numerically.

15.5

':~Y:::~;'~:~!~i~!~~ifl:;:~~:');:::':;:;
Parts Machines
1 2 3

15.6 1S.6

order clustering technique to the part-machine incideuce matrix i in thetol. Apply the lire rank order clustering technique part-machine incidence n the following fy logical pan part families and imchine lo,,;ng tabic table \a to identi identify machine groups. groups. Parts Parts are identified by by letletare identified tersand identified numerically numerically ters. and machines machines are identified
.

45.

Chap. 15 Chap.15

I Tecbnoto qv end Cellular / Group GroupTechnologyand Cellular Manufacturing Manufacturing

Parts Parts

Machines Machines
1
2

ABCDEFGH

3 4 5 6 7 8

15.7

Apply the rank order order clustering clustering technique technique to io the part-machine part-machine incidence incidence matrix matrix in the the folfolth rank lowing ig table table to to identify identify logical logical part part families families and and machine machine groups. groups. Parts Parts are are identified identified by by letletlowing ta are tees, and machines machines s are identified numerically. ters, and are identifie identified numerically.

Parts Parts

Machines Machines
1

ABCDEFQHI A

2
3 d 5 6 7 8 1 1
1

1 1

15.8 15.8

The ten parts The following following table table lists lists the the weekly weekly quantities quantilies and and routings routings of often parts that thai are are being being oonconp Iters,andn mastdered Parts and rnasidered for cellular cellular manufacturing manufacturing in a machine machine shop. shop.Pa rts are identified identified hylettcrs, hy letters
.

chine ss are identified nur hine inciden chines are identified numerically. data given, given, (a) the parl-machin part-machine incidence Ltnerically. For For the the data (a) develop develop the matrix.and arrix.and (b) apply the Tank rank order order clustering clustering technique technique 10the to the part-machine part-machine incidence incidence rnamatri i to trix to identify identify logical in logical part pari families families and and machine machine groups. groups.

Problems

457 457

P,rt Part
A 8 C
D E

Weekly

Quantity Weekly Quantity

Machine

Routing Machine Routing

Part Part

Weekly

Weekly Quantitv Quantity

60 60 5 6 100 100 40 40 15 15

Machine Routing Machine Routing

50 50 20 20 75 75
10 10 12 12

3 2 .7 3--t2--t7 6-1 6~1 6-.5 6~5 6--t5 .... 1 6--5->1

F G H
I J

5 ..... , 5 - 1 3 ..... 2...,.4 3-.2->4 3 _ 2 _4...,.7 3_*2-*4-*7 2...,. 4-t7 4 ...,.7 2 5...,>6...,.1 5-*6-*1

3--t2 .... 7...,.4 3->2--7 4

Machine Machine Cell Organization Organization and Design Design 15.9 Four four machines machines used to produce produce a family of parts parts are to be arranged arranged into into a GT GT cell. The The From-To the parts pf<)cess~dby the machine~ the table Ftom-To data data for the processed by the jnachines are shown in the table below. below, (a) Deterrnine termine the most logical sequence sequence of machines machines for this data using Hollier Hollier Method Method I. 1. (b) Construct the flow diagram for the data, showing where and how many parts enter and exit the parts enter diagram data showing system. Compute the percentage system, (c) Compute percentage of in-sequence in-sequence moves and and the percentage percentage of backtracking feasible layout plan for the cell tracking moves in the the solution. solution, (d) Develop Develop a feasible cell.
,

To:
From:

12 0

3 0

4 40 40

2
3 4

0 o
50 50 0 o

10 10

0
0 0 50 50

0
0 0

0 0 20 20 0 0

15.10 1S.10 15.11 1S.11

Solve Problem Problem 15.9 except using Hollier Hollier Method Method 2. In Problem Problem 15.8. 15.8. two logical machinr: machine groups groups are identified identified by rank rank order order clustering. clustering For each machine group, group (a) determine determine the most logical sequence sequence of machines machines for this data data using Hollier Method Hollier Method 1. 1. (b) Construct Construct the flow diagram diagram for the data. data (c) Compute Compute the percentage percentage of in-sequence moves in the solution in-sequence moves and the percentage percentage of backtracking backtracking moves solution.
,
,

15.12

Solve Problem Problem 15.11 15.11 only using using Hollier Hollier Method Method 2.
,

15.13 Five machines will constitute a UT UT cell.The cell. The From-To From- lo data tor for the machines machines are shown in the 15.13 will constitute table below. below, (a) Determine Determine the most logical sequence sequence of machines machines lor for this data, data according according to Hollier diagram for the data.showing Hollier Method Method Land Land construct construct the flow diagram data showing where where and how many parts enter and exit the system. (b) Repeat step (a) only using Hollier enter system, Repeat Hollier Method Method 2, 2. (c) Compute the percentage percentage of in-sequence in-sequence moves and the percentage percentage of backtracking backtracking moves moves in the method is better.according better according to these solution for the two methods. Which method these measures? measures? (d) Develop a feasible layout better of the two Hollier layout plan for the cell based based on the better Hollier methods. methods
.
,
.

To: To:

crom: From' 1 2 3
4

7 0 0 o 0 o 0 o

2 10 10 0 o 0 o 0 o 75

3 80 0 0 o

4 0 o

5 0 0 0
0

o
0 o

85
0 o 0 o

70 70

20 20

20

458
15.14

Chap, Chap. 15 15

I / Group Group Technology Technologv and and Cellular Cellular Manufacturing Manufacturing

A GT machine cell contains three machines. Machine 1 feeds machine 2. which is Ihe key ma-

chine in the cell. Machine 2 feeds machine 3. The cell is set up to produce a family of live

pai Is (A, B. C, D, and E). The operalion limes for each part at each machine are given in the table below. The products are to be produced in the ratios 4:3:2:2:1. respectively, (a) If 35
hrs/wk arc worked, determine how many of each product will be made by the ccll.(b) What
is the utilization of each machine in the cell?
Operation Operation

----Part Part A B C D E Machine 1 1 Machine

nme Time (min) (min)

Machine 3 3 Machine

Machine 2 Machine 16.0 15,0

4.0 15.0 26.0 26.0 15.0 8.0 8.0

18.0
20.0 20,0 20.0 20.0 16.0 16,0

10.0 7.0 15.0 10.0 10.0

15.15

This problem problem is concerned concerned with the Ihe design of a GT GT cell to lo machine the components componenls for a f<IIII' family of of part*. part~ The The parts parts come come in several several different different sizes, and and the cell will be designed designed to quickly change change over over from next.This will be be accomplished fast-change fixtures fixtu-es accomplished using using fasl-change lv from one one size size to lo the the next.This
and distributed distr;hllled d numerical control (ONe) programs from from the the plant and numerical control (DNC) to download download the the NC NC programs plant

computer ID to the cell.The parts computer the CNC machines machines In m the cell.The parts are are rotational rolalional type, so the cell must be perform turning, grind ing operaticns.Acable to perform turning boring. boring, facing, drilling, drilling, and and cylindrical cylindrical grinding operations. Accordingly. there there will will be several several machine machine tools in the cell, cell, of of types and and numbers numbers to be specifled by the designer designer To transfer fied transfer parts parts between between machines machines in the cell cell,, the designer designer may elect to use a belt or or similar conveyor conveyor system.Any system. Any conveyor conveyor equipment equipment of this type will be 0.4 m The arrangement arrangement of the various wide. The various pieces of equipment equipment in the cell is the principal principal probprobconsidered. The lem to be considered. The raw workpans workparts will will be delivered delivered into the m~chine machine cellon cell on a bell belt The finished conveyor. The finished parts pans must be deposited deposited onto onto a conveyor conveyor that that delivers them them to the department. The assembly department. The input and output output conveyors are are 0.4 ill m wide, and the designer designer must where they specify where they enter enter and exit the cell.The cell.The parts parts are are currently currently machined machined by conventionconventionmethods in a process-type al methods process-type layout. In the current current production production method, method, there there are seven machi[\e~ involved, involved, but chines bul two of the machine, machines are duplicates. duplicates. From-To From-To data data have been been collected collected for the jobs that that are relevant relevant to this problem. problem.
,

To: To:

From: From:
1 2 3 4 5

7
0 12 74 74 0 0

2 112 0 0 82 73

3 3

4
61 61

S 5

6 6

7 0 0 180 5 0

Parts Out Out Parts

0 45 45 0 0

0 0 0 0 0

59 0
31 31

53
226 226 0 0

0 35 0 0

0 0

23
23 23

16
14 14

6 7
Parts in in Parts

OO00C00 0 0 C 0 0 0 174 25

325 325 0 0

16 16 0

20 300

30 0

20

0 0 0 0

0 75

Problems

459
The lhc FromFrom- To To data indicate the number of workparts moved between machines during a

typical 40-hr week. The data refer to the parts considered in rhe case. The two categories
"

parts in and "parts out " indicate pans entering and exiting the seven-machine group. A total
"

of 400 parts on average are processed through the seven machines each week. However, as
red by the data, not all 400 parts are processed by every machine. Machines 4 and 5 are

Tdi.ntical.and assignment of parts to these machines is arbitrary.Average production

parity on .?ach of the machines for the particular distribution of this parts family is gi' the table below. Also given are ihe floor space dimensions of each machine in ractci ic that all loading and unloading operations take place in the center of the machine.

Machine lachine

Operation Operation

eduction Rat Production Rate (pcjhr! Ipc/hr)

Machine Dimensions Machine Dimensions

1 2 3 4

Turn outside Turn outside diameter diameter Bore inside inside diameter Bore diameter Face ends ends Face Grind diameter Gnnd outside outside diarneter

9
15 15 10 10 12 12

3.5 m x 1.5 m 3.5m x 1-5m 3.0 m x 1.6 m 3,Om x 1.6m 2.5 m x 1.5 m 2.5m x 1.5m 3.0m x 1.5m 3.0m x 1.5m

Grind diameter Grind outside outside diameter

Inspect Inspect

12 12
5

3.0 m x 7,5 m 3.0m x 1.5m

Bench x 1.5 m Bench 1.5 m x m

6
7

Drill Drill

9 9

1.5 m X 2.5 m 1.5m x 2.5m

OperaTion 6 is currently a manual inspection operation. It is anticipated that this manual station will be replaced by a coordinate measuring machine (CMM).This automated inspection machine will triple througbpul rate to 15 parts/hr from 5 parts/hr for the manual method. The floor bpa;e dimensions of the CMM arc 2.0 m X 1 6 m. All other machines
.

currently listed are to he candidates for inclusion in the new machine cell, (a) Analyze the

problem and determine the most appropriate sequence of machines in the cell using the data contained in the from-To chart, (b) Construct the flow diagram for the cell showing
,

d how many parts enter and exit the cell (c) Determine the utiliiation and pro,

duction capacity of the machines in the cell as you have designed it (d) Prepare a layout (top
.

view) drawing of the GT cell showing the machines, Ihe robot(s), and any other pieces of
,

equipment in the cell, (c) Write a one-page (or less) desciiplion of the cell explaining the basis ol your design and why ihe cell is arranged as it is
,
.

chapter 16 16 chapter

Flexible Manufacturing Manufacturing Systems Flexible

CHAPTER CONTENTS CHAPTER CONTENTS

16.1 What Is an FMS? 16.1 WhallsanFMS?
16.1.1 16.1.1 What What Makes Makes It It Flexible? Flexible? 16.1.2 TypesofFMS Types of FMS 16.1.2 16.2 FMS Components Components 16.2 FMS 16.2.1 Workstations 16.2.1 Workstations

16.2.2 Storage System 16.2.2 Material Material Handling Handling and and Storage System 16.2.3 Control System 16.2.3 Computer Computer Control System 16.2.4 Human Human Resources 16.2.4 Resources

Applications and Benefits 16.3 FMS Applications and Benefits

16.3.1 16.3.1 FMS FMS Applications Applications

16.3.2 FMS Benefits 16.3.2 FMSBenefits

16.4 FMS 16.4 FMS Planning Planning and and Implementation Implementation Issues Issues 16.4.1 Planning and Design Design Issues 16A1 FMS FMS Planning and Issues 16.4.2 FMS Operational Issues 16.4.2 FMS Operational Issues 16.5 Quantitative Analysis of Flexible Flexible Manufacturing Systems 16.5 Quantitative Analysis of Manufacturing Systi

16.5.1 Bottleneck Model 16.5.1 Bottleneck Mode! 16.5.2 Extended Bottleneck Model 16.5.2 Extended Bottleneck Model

16.5.3 SizingtheFMS 16.5.3SizingtheFMS 16.5.4 What What the Tell 16.5.4 the Equations Equations Tell Us Us

The flexible flexible manufactur manufacturing system (FMS) (FMS) was identified in the the lasi last chapter chapter as one one of of the the The ing system was identified machine cell types used used to to implement implement group group technology.lt technology. It is the the most and techmachine cell types most automated automated and technologically sophisticated the GT GT cells. In our our classification classification scheme for manufacturing manufacturing sysnologically sophisticated of of the scheme for
460