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Group Technology and Cellular Manufacturing: Presented by

Group technology and cellular manufacturing aim to improve manufacturing efficiency. Group technology involves grouping parts into families based on similar design attributes and manufacturing requirements. Machines are also grouped to match part families. This allows manufacturing cells to be formed where a cluster of machines dedicate to producing a family of parts. Cellular manufacturing reduces setup times, flow times, inventories and improves flexibility, utilization and throughput. Effective cell design considers both structural issues like equipment selection and layout, as well as operational issues to optimize performance.

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Nilesh Satpute
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43 views

Group Technology and Cellular Manufacturing: Presented by

Group technology and cellular manufacturing aim to improve manufacturing efficiency. Group technology involves grouping parts into families based on similar design attributes and manufacturing requirements. Machines are also grouped to match part families. This allows manufacturing cells to be formed where a cluster of machines dedicate to producing a family of parts. Cellular manufacturing reduces setup times, flow times, inventories and improves flexibility, utilization and throughput. Effective cell design considers both structural issues like equipment selection and layout, as well as operational issues to optimize performance.

Uploaded by

Nilesh Satpute
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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1

GROUP TECHNOLOGY AND CELLULAR


MANUFACTURING

Presented by

Nilesh Satpute
Swati Shitanshu
WHAT IS GROUP TECHNOLOGY?
2

Group technology (GT) is a philosophy that implies


the notion of recognizing and exploiting similarities
in three different ways:
1. By performing like activities together
2. By standardizing similar tasks
3. By efficiently storing and retrieving
information about recurring problems
3

Large manufacturing system can be


decomposed into smaller subsystems of part
families based on similarities in

1. design attributes and 2.


manufacturing features
DESIGN ATTRIBUTES:
4

 part configuration (round or prismatic)


 dimensional envelope (length to diameter ratio)
 surface integrity (surface roughness, dimensional
tolerances)
 material type
 raw material state (casting, forging, bar stock, etc.)
PART MANUFACTURING FEATURES:
5

 operations and operation sequences (turning,


milling, etc.)
 batch sizes
 machine tools
 cutting tools
 work holding devices
 processing times
6

The Basic Key Features for a Successful Group


Technology Applications:

• Group Layout
• Short Cycle Flow Control
• A Planned Machine Loading
Group Layout
7

In most of today’s factories it is possible to divide all


the made components into families and all the
machines into groups, in such a way that all the parts
in each family can be completely processed in one
group only.
The tree main types of layout are
• Line Layout
• Group Layout
• Functional Layout
Line Layout
8

Line Layout is used at present in simple


process industries, in continuous assembly, and
for mass production of components required in
very large quantities.
Functional Layout
9

In Functional Layout, all machines of the same


type are laid out together in the same section
under the same foreman. Each foreman and his
team of workers specialize in one process and
work independently. This type of layout is
based on process specialization.
Group Layout
10

In Group Layout, each foreman and his team


specialize in the production of one list of parts
and co-operate in the completion of common
task. This type of layouts based on component
specialization.
BENEFITS OF GROUP TECHNOLOGY
11

Group technology is a management


strategy to help eliminate waste caused by
duplication of effort.
BENEFITS OF GROUP TECHNOLOGY
12

It affects all areas of a company, including:

 engineering
 equipment specification
 facilities planning
 process planning
 production control
 quality control
 tool design
 purchasing
 service
CELLULAR MANUFACTURING
13

Cellular manufacturing is an application of group


technology in manufacturing in which all or a
portion of a firm’s manufacturing system has been
converted into cells.
CELLULAR MANUFACTURING
14

A manufacturing cell is a cluster of machines or


processes located in close proximity and dedicated
to the manufacture of a family of parts.

The parts are similar in their processing


requirements, such as operations, tolerances, and
machine tool capacities
The primary objectives in implementing a cellular
manufacturing system are to reduce:
15

 setup times (by using part family tooling and


sequencing)
 flow times (by reducing setup and move times and
wait time for moves and using smaller batch sizes)
 reduce inventories
 market response times
16

In addition, cells represent sociological units that have


more tendency to teamwork. This means that
motivation for process improvements often arises
naturally in manufacturing cells.

Manufacturing cells are natural candidates for just-


in-time (JIT) implementation.
Functional and cellular layouts of an electronics plant:

17
Cell Design
18

Design of cellular manufacturing system is a


complex exercise with broad implications for an
organization.

The cell design process involves issues related to


both system structure and system operation
Structural issues include:

19
 Selection of part families and grouping of parts
into families
 Selection of machine and process populations
and grouping of these into cells
 Selection of tools, fixtures, and pallets
 Selection of material-handling equipment
 Choice of equipment layout
Issues related to procedures include:

20

 Detailed design of jobs


 Organization of supervisory and support personnel
around the cellular structure
 Formulation of maintenance and inspection policies
 Design of procedures for production planning,
scheduling, control, and acquisition of related
software and hardware
 Modification of cost control and reward systems
 Outline of procedures for interfacing with the
remaining manufacturing system (in terms of work
flow and information, whether computer controlled or
not)
Evaluation of Cell Design Decisions
21

The evaluation of design decisions can be


categorized as related to either
 the system structure
or
 the system operation.
Typical considerations related to the system
22
structure include:

 Equipment and tooling investment (low)


 Equipment relocation cost (low)
 Material-handling costs (low)
 Floor space requirements (low)
 Extent to which parts are completed in a cell (high)
 Flexibility (high)
Evaluations of cell system design are incomplete
23 unless they relate to the operation of the system.

A few typical performance variables related to


system operation are:

 Equipment utilization (high)


 Work-in-process inventory (low)
 Queue lengths at each workstation (short)
 Job throughput time (short)
 Job lateness (low)
Production flow analysis involves four stages:
24

Stage 1: Machine classification.

Machines are classified on the basis of operations


that can be performed on them. A machine type
number is assigned to machines capable of
performing similar operations.
25

Stage 2: Checking parts list and production


route information.

For each part, information on the operations to be


undertaken and the machines required to perform
each of these operations is checked thoroughly.
Stage 3: Factory flow analysis.
26

This involves a micro-level examination of flow of


components through machines. This, in turn, allows
the problem to be decomposed into a number of
machine-component groups.
Stage 4: Machine-component group analysis.
27

An intuitive manual method is suggested to


manipulate the matrix to form cells. However, as
the problem size becomes large, the manual
approach does not work. Therefore, there is a need
to develop analytical approaches to handle large
problems systematically.
28

Thank You!!!!!!!

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