Advanced Manufacturing Systems Design © 2000 John W. Nazemetz Group Technology Definition and Concepts

Advanced Manufacturing
Systems Design
2000 John W. Nazemetz
Lecture 5 Topic :
Group Technology
Definition and
Concepts
Segment A Topic:
ADVANCED
MANUFACTURING
SYSTEMS DESIGN
Group Technology
Definition and Concepts
Slide 2
Computer Integrated
Manufacturing Systems
Overview
Group Technology
Definitions
Concepts
Slide 3
Computer Integrated
Group Technology
Definition (1)
Definition
Group Technology is an operating
management philosophy based on the
recognition that similarities occur in the
design and manufacture of discrete parts.
Group Technology exploits the similarities
among attributes of objects for the
purpose of performing a known function.
The attributes may be physical or process
oriented.
Slide 4
Computer Integrated
Group Technology
Definition (2)
Alternate Definition (Webster)
Group
To Combine in a Group, to Assign to a
Group, Synonymous with Classify
Technology
An Applied Science, A Technical Method to
Achieve a Practical Purpose.
GT => A Technical Method of Group

Formation
Slide 5
Computer Integrated
Group Technology
-Applications
Applications
Design
Similar Shapes
Similar Processing
Group Scheduling
Sequence Dependant Set Ups
Cellular Manufacturing (Decomposition

of Manufacturing Problem)
Logical Cells
Physical Cells
Slide 6
Computer Integrated
Group TechnologyBenefits
Design
Manufacturing
Part Standardization
Reduces Inventories
Reduces Managerial
Complexity
Access to
Manufacturing
Process Information
Increased Designer
Productivity
Slide 7
Increase
Throughput
Reduce Variability
Improve Inventory
Management
Reduce Set Up
Improve Efficiency
Improve Quality
Simplify Procedures
Reduce Tooling
Computer Integrated
Classification and
Coding (1)
Classification
Grouping of Like Things
Based on Physical or Process
Attributes
Logical and Systematic
Coding
Shorthand Notation for Complex Ideas
Slide 8
Computer Integrated
Classification and
Coding (2)
Classification
All - Embracing
Mutually Exclusive
Based on Permanent Characteristics
Reflect Users Objective and
Nomenclature
Coding
Set of Symbols to which a Meaning has
been Assigned
Will Database Technology Render Coding
Obsolete?
Slide 9
Computer Integrated
Group Technology
Grouping Attributes (1)
Shape
Form Features
Treatments
Functions
Size Envelopes
Tolerance
Slide 10
Computer Integrated
Group Technology
Grouping Attributes (2)
Surface Finish
Material Type/Condition
Quantity
Next Assembly
Raw Material Form
(Others Based on
Application/User)
Slide 11
Computer Integrated
Group Technology
Grouping Methods
Visual Inspection of Existing Parts
Usually Done As Parts are Made
Using Codes Defined During Design

Pattern Recognition (Similarity)
Features
Processes
Query
Characteristics in Database
Derived Attributes
Additionally Input Attributes
Slide 12
Computer Integrated
Monocode (1)
Additional Digits Amplifies
Previous Digit
Digit 1 = 1 -> Component
Digit 2 = 4 ->Cylinder
Digit 3 = Diameter, Digit 4 = Length,
Digit 2 = 5 -> Rectangular

Digit 3 = Length, Digit 4= Width,
Digit 5 = Height, etc
Slide 13
Computer Integrated
Monocode (2)
Previous Digit
Digit 1 = 2 -> Assembly
Digit 2 = ->Assembly Method
1 = Mechanical
Digit 3 = -> Assembly Parameter

IF Digit 2 =1, Digit 3= Type of Fastener
IF Digit 2 = 2 (Weld), Digit 3 = Type (Arc,
)
Slide 14
Computer Integrated
Monocode (3)
Previous Digit
Large Number of Combinations
Possible
N1 x N 2 x N 3 x N 4 x N n
Difficult for Human Interpretation

Cannot Sort on Single (Internal)
Digit
Meaning Dependant on Preceding Digit
Slide 15
Computer Integrated
Polycode
Each Digit Has Single Meaning
Combinations Possible
N1 + N 2 + N 3 + N 4 + + N n
Block Code Not Difficult for

Human Interpretation
Can Sort on Single (Internal) Digit
Meaning Independent of Preceding
Digit
Long Codes May Result

Slide 16
Computer Integrated
Mixed Codes
Combines Mono- and PolyCoding
Attempt to Shorten Code while
Allowing a Larger Number of
Possibilities
Slide 17
Computer Integrated
Is Coding Obsolete? (1)

Should Actual Data be Used vs.
a Code Which Inexactly
Represents It?
Attributes can be Derived and
Stored Automatically
I.e., Largest Dimension = Length
Use Database Search Engine/Query
to Find Groups
Dynamic Not Predefined, Flexible
Slide 18
Computer Integrated
Is Coding Obsolete? (2)

Not Quite Yet
Coding Is Efficient
Legacy Systems Use Coding
Coding Embedded in Corporate
Culture
Slide 19
Computer Integrated
Using Database
Elements for Grouping
(1)
Problems
Speed of Search
Requirement to Exact Match,
Control of Alphanumeric Elements
Synonyms
Is 1020 same as 1020 Steel?
Spelling
Is ALUM same as Alum same as Aluminium?
Confusion
Is 305 a Stainless or a Tool Steel?
Slide 20
Computer Integrated
Using Database
(2)
Solutions
Indexing Data to Speed Search
Quicker to Search Numeric Fields
Use Multiple Stage Searches (Code?)
Requirement to Exact Match,

Control of Alphanumeric Elements
Use Drop-Down Selections to Control
Input (Must be all-inclusive)
Can Allow Editable Drop Downs But
Maintenance is Required.
Slide 21
Computer Integrated
Using Database
(3)
Maintenance
Make System Data Driven
No Hard Coding
Higher Initial Cost
Lower Maintenance
Requires Diligence and Discipline
Slide 22
Computer Integrated
Systems Design
Lecture 5 Topic :
Group Technology
Definition and
Concepts
Segment A Topic:
END OF SEGMENT
Systems Design
Lecture 5 Topic :
Group Technology
Segment B Topic:
Example
ADVANCED
MANUFACTURING
SYSTEMS DESIGN
Group Technology
Example - GTSS
Slide 25
Computer Integrated
GTSS
Group Technology Selection System
Developed for DLA to Assist in
Acquisition
Developed as Part of the CATT Program
Slide 26
Computer Integrated
Overall Mission
Facilitate the Part Acquisition Process
Identify Manufacturers with Particular
Capabilities
Grouping of Parts by their Similarities
Enable Mapping of Manufacturers to
Individual or Groups of Parts Using
Group Technology and Information
Technologies
Slide 27
Computer Integrated
Project Initiative
Create National and Local Versions of

Part and Vendor Information System
DLA Deployment (DSCR, DSCC)
SCRA, DSCC, DSCR, OSU
Captures only manufacturers with CAGE
codes
Oklahoma Deployment
CATT -- CDS, GTI/ICI Group, OKC-ALC
Captures Oklahoma manufacturers
Slide 28
Computer Integrated
GTSS Information Flow

High-Level Inputs
High-Level Output s
Vendor
Database
SAMMS
FSC, NIIN, WSC,
Part Name, Part No.,
Cage Code, Dwg No./Rev.
SAMMS
Parts
to be coded
or procured
GTSS
Value Engr. Division
Update
TDPs
File of
GT cod ed
Parts
via
JEDMICS
Vendor
Data
Reports
Grouping
Mapping
Slide 29
Computer Integrated
System Functions
NSN Data Entry
Identification Data
GT Code Generation
Vendor Data Entry

Identification Data
Capabilities
Grouping
Mapping
Slide 30
Data Manipulation
Computer Integrated
Entry/Edit Data
Error Checking
File Import/Export
Data Display (Search)
Data Display (Filter)
Data Display (Sort)
Vendor Queries
Report Generation
Systems Design
Concepts
COTS Software
Graphical Interface
Windows 95
PowerBuilder
Oracle
Easy to Use
Intuitive
Simple
Security
Group Technology
Passwords
User Levels
Part Feature Based Part

and Vendor Codes
On-Line Help
Data Driven
Ease of Maintenance
Slide 31
Easy to Use
Computer Integrated
Data Base Design

Concepts
Balance Data Detail Level, DB Size

Longer/Deeper Code
Better Data Resolution, But
Data Base Grows Exponentially
Use Auxiliary Fields to Reduce DB Size
Hybrid Group Technology Code

First Positions used to Define Rest of
Code
Same Code for Vendors and Parts
Parts have a Single Code
Vendors have Multiple Codes
Slide 32
Computer Integrated
Data Base Design

Concepts (cont.)
Impact of Code Length/Depth on DB
Number of categories is product of number
of positions and number of possible
selections
Example: For a 10 position code with each
code position having 5 possible selections,
9,765,625 possible
combinations/categories
While a part would have only one code, a vendor
who can make everything has nearly 10 million.
Slide 33
Computer Integrated
Data Base Design

Concepts (cont.)
Impact of Auxiliary Fields
If data is stored in an auxiliary field
rather than a code digit, DB size is
reduced
Example: if auxiliary field were used to
reduce a 10 position, 5 selection code
to 7 positions, 5 selections, the
number of possible combinations is
78,125, not 9,765,625
Slide 34
Computer Integrated
Data Base Design

Concepts (cont.)
Data in GT Code
Material Type [2]

Shape
[4]
Raw Matl Form [4]
Alt. Matl Form
[4]
Size
[5,30]
Tolerances
[4]
Quality [4]
Data in Auxiliary
Fields
Material Spec Type

Material Spec
Plating
Treatment
Coating
Material Name
approximately
53,760 possible
categories
Slide 35
Computer Integrated
if these fields in
code @ 10
selections each,
one half trillion
categories
GT Code Design
Concepts
First Two Code Positions Are Fixed
Part Type (Initial Project Scope)
Mechanical Piece Part
Mechanical Subassembly
Shape
Prismatic, Cylindrical, Sculptured, Gears
Not Used for subassemblies
Slide 36
Computer Integrated
GT Code Design
Concepts (cont.)
Remaining Code Elements

Piece Parts
Slide 37
Size
Tolerances
Raw Material Form
Alt. Raw Material Form
Quality Req.
Subassemblies
Computer Integrated
Kitted/Assembly
Weight
Size
Fabrication/Machinin
g
Tolerances
Quality Req.
GUI Design Concepts

Follows WINDOWS Standards
Main Toolbar w/Dropdown menus
Relocatable Icon Toolbar
Right Mouse Button Activated
Response Windows
Context Sensitive Help Available
Dynamic Error Checking
Slide 38
Computer Integrated
Summary/Assessment
Concepts
Theoretically Sound
Method of Coding Manufacturers Was
Awkward
Problems
No Funds for Legacy Part Coding
Use
Used to Identify Suppliers
Slide 39
Computer Integrated
Systems Design
Lecture 5 Topic :
Group Technology
Segment B Topic:
Example
END OF SEGMENT
Systems Design
Lecture 5 Topic :
Group Technology
Grouping
Analysis Methods
Segment C Topic:
ADVANCED
MANUFACTURING
SYSTEMS DESIGN
Group Technology
Grouping Analysis Methods
Slide 42
Computer Integrated
Overview
Grouping/Analysis Methods
Production Flow Analysis
Rank Order Clustering
Similarity Indexes
Single Linkage
Weighted (Production Volume)
Mathematical Programming
NOTE: The Following Slide Materials are

From Singh, Systems Approach to
Computer Integrated Design and
Manufacturing, p. 490-499.
Slide 43
Computer Integrated
Production Flow
Analysis
Slide 44
Computer Integrated
Productio
n
Flow
Analysis
Matrix
Manipulation
Row and Column
Sorting
Slide 45
Computer Integrated
Rank Order Clustering

(1)
Slide 46
Computer Integrated
Rank Order Clustering (2)
Slide 47
Computer Integrated
Rank Order Clustering (3)
Slide 48
Computer Integrated
Single Linkage Cluster

Algorithm (1)
Slide 49
Computer Integrated

Algorithm (2)
Slide 50
Computer Integrated

Algorithm (3)
Slide 51
Computer Integrated
Siefoddini and Wolfe

Considers Production Volume
(Weighted Average)
Slide 52
Computer Integrated
Exceptional Parts and

Bottleneck Machines
Practical Approach to Problem of
Costly Equipment
Allow InterCell Movement
Elimination
Generate Alternate Processing Plans
Duplicate Machines
Subcontracting Operations
Still Has InterCell Transfers
Slide 53
Computer Integrated
Alternate Cell
Configurations (SLCA)
Slide 54
Computer Integrated
Alternate Cell
Configuration Analysis
Why
Cell
One?
Slide 55
Computer Integrated
Mathematical Models
Cell Design with Known Part Families
Minimize Machine Investment
Cell Design with Unknown Part Families

Minimize Machine Investment
Constrains Maximum Number of Machines
in Cell
Cell Design With Unknown Part

Families, Key Machines
Minimize Investment,
Movement/Backtracking
Slide 56
Computer Integrated
Grouping Efficacy
Method for Evaluating Goodness of
Fit
Slide 57
Computer Integrated
Systems Design
Group Technology
Grouping -Analysis Methods
Discussion Topic C:
END OF SEGMENT

Advanced Manufacturing Systems Design © 2000 John W. Nazemetz Group Technology Definition and Concepts

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Advanced Manufacturing Systems Design © 2000 John W. Nazemetz Group Technology Definition and Concepts

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Advanced Manufacturing

2000 John W. Nazemetz

2000 John W. Nazemetz

2000 John W. Nazemetz

GT => A Technical Method of Group

2000 John W. Nazemetz

Cellular Manufacturing (Decomposition

2000 John W. Nazemetz

2000 John W. Nazemetz

2000 John W. Nazemetz

2000 John W. Nazemetz

2000 John W. Nazemetz

2000 John W. Nazemetz

Using Codes Defined During Design

2000 John W. Nazemetz

Digit 2 = 5 -> Rectangular

2000 John W. Nazemetz

Digit 3 = -> Assembly Parameter

2000 John W. Nazemetz

Difficult for Human Interpretation

2000 John W. Nazemetz

Block Code Not Difficult for

Long Codes May Result

2000 John W. Nazemetz

2000 John W. Nazemetz

Is Coding Obsolete? (1)

2000 John W. Nazemetz

Is Coding Obsolete? (2)

2000 John W. Nazemetz

2000 John W. Nazemetz

Requirement to Exact Match,

2000 John W. Nazemetz

Requires Diligence and Discipline

2000 John W. Nazemetz

2000 John W. Nazemetz

2000 John W. Nazemetz

2000 John W. Nazemetz

Create National and Local Versions of

2000 John W. Nazemetz

GTSS Information Flow

2000 John W. Nazemetz

Vendor Data Entry

2000 John W. Nazemetz

Part Feature Based Part

2000 John W. Nazemetz

Data Base Design

Balance Data Detail Level, DB Size

Use Auxiliary Fields to Reduce DB Size

Hybrid Group Technology Code

2000 John W. Nazemetz

Data Base Design

2000 John W. Nazemetz

Data Base Design

2000 John W. Nazemetz

Data Base Design

Material Type [2]

Material Spec Type

2000 John W. Nazemetz

2000 John W. Nazemetz

Remaining Code Elements

2000 John W. Nazemetz

GUI Design Concepts

2000 John W. Nazemetz