ADVANCED MANUFACTURING SYSTEMS

(ME-431)

Lecture – 2

Types of Production Systems,

Group technology and Cellular Manufacturing System

Course Instructor: Dr. Ammar ul Hassan

Email Id: [email protected]

Department of Mechanical Engineering,

University of Engineering & Technology,
Taxila
 Types of Production

Production Process

 The production process definition refers to the

steps followed to convert an input into an output.

 It involves utilizing and combining economic

resources like land and capital and processing them
to provide products and services for consumers.

 It is simply defined as changing inputs into outputs.

 Types of Production

Objectives

 The objectives of the production process include;

meeting market demands and Substituting products
 Types of Production

Types of Production Process

The five main types of production are

1. Mass production,
2. Batch production,
3. job production and
4. just-In-Time production, and
5. flexible manufacturing system.
 Types of Production

Types of Production Process

1. Mass production,

 Mass production, also known as flow production or continuous

production, is the production of substantial amounts of
standardized products in a constant flow.

 Mass production is the industrial technique to produce large

quantities of similar products in constant flows on production
lines.
 Types of Production

Types of Production Process

1. Mass production,

 The mass production process constitutes assembly lines and

automation technology to provide goods in bulk.

 The main features of mass production include division of labor

as each production process requires a different machine, a
smooth flow production with product flow clearly defined
standardization to achieve high quality, and high startup costs
due to the many resources required before operations.
 Types of Production

Types of Production Process

2. Batch production,

 Batch production is a method whereby a group of identical

products are produced simultaneously (rather than one at a time).

 Batch production is a method of manufacturing where the products

are made as specified groups or amounts, within a time frame

 The production process in batch production is the same goods go

through different stages to create the same output.
 Types of Production

Types of Production Process

2. Batch production,

 It constitutes of batches, group production, and the same

machinery.

 The main features of the batch process include repetitive

processes, machines of the same type arranged strategically in
the same production process, and a set layout and elements
include group customization, which involves changes to be
made and reuse of equipment's
 Types of Production

Types of Production Process

3. Job Production,

 Job production is a process that constitutes workers making a

single, standardized, and unique goods for a specific customer.

 Its features include many machines, a large number of experienced

employees, varying production methods, and standardized goods.

 The elements are large inventories, adjustable machine settings,

and intermittent movement of Materials.
 Types of Production

Types of Production Process

4. Just in Time Production,

 Just-in-time manufacturing (JIT manufacturing) is a

production model in which items are created to meet
demand, not created in surplus or in advance of
need.

 Organizations adopt the JIT approach to increase

efficiency, reduce costs and speed up product delivery
 Types of Production

Types of Production Process

5. Flexible Manufacturing System,

A flexible manufacturing system is a manufacturing system

in which there is some amount of flexibility that allows
the system to react in case of changes, whether
predicted or unpredicted.
 ©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book

Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 20/50
Group Technology and Cellular
Manufacturing System
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Group Technology
Group Technology
2
9

Implementing GT

Where to implement GT?

 Parts using traditional batch production
 If the parts can be grouped into part families

How to implement GT?

 Identify part families
 Rearrange production machines into machine cells
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Types of Layout

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 three main types of layout are:

• Line (product) Layout
• Functional Layout
• Group Layout
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1

Line (product) Layout

•It involves the arrangements of machines in one line, depending on
the sequence of operations. In product layout, if there is a more than
one line of production, there are as many lines of machines.
•Line Layout is used at present in simple process industries, in
continuous assembly, and for mass production of components
required in very large quantities.
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Functional Layout

•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.
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3

Group Layout

•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.
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The Difference between group and functional layout

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Identifying Part Families

Large manufacturing system can be decomposed into smaller

subsystems of part families (A part family is a collection of parts
that are similar either because of geometric shape and size or
because similar processing steps) based on similarities in

1. design attributes and

2. manufacturing features
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Identifying Part Families

3
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Identifying Part Families

Design Attributes:

 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.)
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Identifying Part Families

Part Manufacturing Features:

 operations and operation sequences (turning, milling, etc.)

 batch sizes
 machine tools
 cutting tools
 work holding devices
 processing times
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Methods for identifying parts

families

A part family is a collection having similar:

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Forming Part Families –

1. Visual Inspection Method
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1

Forming Part Families –

1. Visual Inspection Method

 incorrect results
 human error
 different judgment by different people
 inexpensive
 good for small companies having smaller
number of parts
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Forming Part Families –

2. Classification and Coding

Coding:
 The process of assigning symbols to the parts. Where the
symbols represent design attributes of parts,
manufacturing features of parts, or both

Classification:
 The process of categorization of a set of parts into part
families
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Example: Optiz part coding System

• Given the rotational part design below, determine the form code in the
Optiz parts classification and coding system.

Solution

• Length-to-diameter ratio: L/D = 1.5 Digit 1 = 1

• External shape: both ends stepped with screw thread on one end Digit 2 =
5
• Internal shape: part contains a through hole Digit 3 = 1
• Plane surface machining: none Digit 4 =
0
• Auxiliary holes, gear teeth, etc.: none Digit 5 = 0

The form code in the Optiz system is 15100

4
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Forming Part Families –

Production Flow Analysis (PFA)

 PFA is a method for identifying part families and

associated machine groupings based on the required
manufacturing processes need for each part
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Cell Formation Approaches

1. Machine - Component Group Analysis:

Machine - Component Group Analysis is based on

production flow analysis
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Machine - Component
Group Analysis
Production flow analysis involves four stages:

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.
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Machine - Component
Group Analysis

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.
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Machine - Component
Group Analysis

Stage 3: Factory flow analysis.

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.
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Machine - Component
Group Analysis

Stage 4: Machine-component group

analysis.
An natural 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.
 Machine - Component
Group Analysis

Example: Consider a problem of 4 machines

and 6 parts. Try to group them.
Components
Machines 1 2 3 4 5 6
M1 1 1 1
M2 1 1 1
M3 1 1 1
M4 1 1 1

50
 Machine - Component
Group Analysis

Solution
Components
Machine 2 4 6 1 3 5
s
M1 1 1 1

M2 1 1 1

M3 1 1 1

M4 1 1 1

51
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Rank Order Clustering Algorithm

Rank Order Clustering Algorithm is a simple

algorithm used to form machine-part groups.
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Rank Order Clustering Algorithm

Step 1: Assign binary weight and calculate a decimal

weight for each row and column using the following
formulas:


m
Decimal weight for row i = bip 2m-p
p=1

b 2
n
Decimal weight for column j = pj
n p

p=1
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Rank Order Clustering Algorithm

Step 2: Rank the rows in order of decreasing

decimal weight values.

Step 3: Repeat steps 1 and 2 for each column.

Step 4: Continue preceding steps until there is

no change in the position of each element in
the row and the column.
 Rank Order Clustering Algorithm

Example:

Consider a problem of 5 machines and 10 parts. Try to

group them by using Rank Order Clustering Algorithm.

Table 1

Components

Machines 1 2 3 4 5 6 7 8 9 10
M1 1 1 1 1 1 1 1 1 1
M2 1 1 1 1 1
M3 1 1 1 1
M4 1 1 1 1 1 1
M5 1 1 1 1 1 1 1 1
55
Rank Order Clustering Algorithm

Table 2 Binary weight

29 28 27 26 25 24 23 22 21 20
Components
Decimal
Machines 1 2 3 4 5 6 7 8 9 10 equivalent

M1 1 1 1 1 1 1 1 1 1 1007
M2 1 1 1 1 1 451
M3 1 1 1 1 568
M4 1 1 1 1 1 1 455
M5 1 1 1 1 1 1 1 1 1020
 Rank Order Clustering Algorithm

Table 3 Binary weight

29 28 27 26 25 24 23 22 21 20
Components
Binary Machines 1 2 3 4 5 6 7 8 9 10
weight
24 M5 1 1 1 1 1 1 1 1
23 M1 1 1 1 1 1 1 1 1 1
22 M3 1 1 1 1
21 M4 1 1 1 1 1 1
20 M2 1 1 1 1 1
Decimal
equivalen
28 27 27 27 28 20 28 26 11 11
t
 Rank Order Clustering Algorithm

Table 4 Binary weight

29 28 27 26 25 24 23 22 21 20
Components
Binary Machines 1 5 7 2 3 4 8 6 9 10 Decimal
weight equivalen
t

24 M5 1 1 1 1 1 1 1 1 1020
23 M1 1 1 1 1 1 1 1 1 1 1019
22 M3 1 1 1 1 900
21 M4 1 1 1 1 1 1 123
20 M2 1 1 1 1 1 115
Decimal
equivalent
28 28 28 27 27 27 26 20 11 11
 Rank Order Clustering Algorithm

• R/O clustering oscillations indicating need of machine replication

(happens often!)
• Presence of Outliers and/or Voids in the finished clusters
• Outliers indicate the need of machine replication
• Voids indicate ‘skipped’ machines in a cell
• Generally speaking, these clustering algorithms are designed to
convert existing routes for facility re-organization
• They require a previous engineering study to be performed to
develop a series of routers on a core sample of parts that represent
most of the production in the shop
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Rank Order Clustering Algorithm

 The ROC provides a simple analytical technique that

can be easily computerized
 The ROC has fast convergence and relatively low
computation time depending on the matrix size
 The fact that ROC uses binary values will impose
restrictions on the size of the matrix that can be solved
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Rank Order Clustering Algorithm

 Most computers have a maximum of 248-1 for integer

representation, which means that the maximum
number of rows and columns is limited to 47
 The algorithm results depend on the initial matrix
arrangement
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Cluster Identification Algorithm

(CIA)

 Designed to identify disconnected blocks if they exist

 If there are no disconnected blocks (the matrix is not mutually

separable), the entire matrix will form one block

 The algorithm begins by masking all columns that have an

entry of 1 in any row (selected randomly), then all rows that
have an entry of 1 in these columns are masked. This process
is repeated until all intersecting columns and rows are masked.
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Cluster Identification Algorithm

(CIA)

 These masked columns and rows are placed in a block

and removed from the matrix.
 Then the process of masking starts again and another
block is identified.
 This will continue until all the entries in the matrix are
assigned in blocks and all separable blocks are identified
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Cluster Identification Algorithm

(CIA)
Example:

Step 1. Select any row i of the incidence matrix and

draw a horizontal line hi through it.
Row 3 of the matrix is selected randomly and a
horizontal line h3 is drawn.
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Cluster Identification Algorithm

(CIA)

Step 2. For each entry of 1 crossed by the horizontal line h3

draw a vertical line vj.
Three vertical lines v2, v6, and v7 are drawn
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Cluster Identification Algorithm

(CIA)

Step 3. For each entry of 1 crossed once by a vertical line vj

draw a horizontal line. A horizontal line h6 is drawn through
all the crossed-once entries of the matrix:
6
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Cluster Identification Algorithm

(CIA)
Step 4. The preceding steps are repeated until no more crossed once
entries are left.
• All the crossed-twice entries are grouped in a block and removed
from the matrix.
•Parts 2, 6, 7 and machines 3, 6 are grouped in one block.
6
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Cluster Identification Algorithm

(CIA)

The grouped parts and machines are removed from the matrix
6
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Cluster Identification Algorithm

(CIA)

Step 5: The above procedure is repeated for the

remaining matrix entries until all entries are grouped
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Cluster Identification Algorithm

(CIA)

The resulting matrix is as follows:

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BENEFITS OF GROUP TECHNOLOGY

Some of the well-known tangible and intangible

benefits of implementing GT :

1. Engineering design
• Reduction in new parts design
• Reduction in the number of drawings through
standardization
• Reduction of number of similar parts, easy
retrieval of similar functional parts, and
identification of substitute parts
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BENEFITS OF GROUP
TECHNOLOGY

2. Layout planning

 Reduction in production floor space

required
 Reduced material-handling effort
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BENEFITS OF GROUP
TECHNOLOGY

3. Specification of equipment, tools, jigs, and

fixtures

 Standardization of equipment
 Significant reduction in up-front costs
incurred in the release of new parts for
manufacture
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BENEFITS OF GROUP
TECHNOLOGY
4. Manufacturing: process planning

 Reduction in setup time and production time

 Alternative routing leading to improved part routing
 Reduction in number of machining operations and
numerical control (NC) programming time
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BENEFITS OF GROUP
TECHNOLOGY

5. Manufacturing: production control

 Reduced work-in-process inventory

 Easy identification of bottlenecks
 Improved material flow and reduced
warehousing costs
 Faster response to schedule changes
 Improved usage of jigs, fixtures, pallets, tools,
material handling, and manufacturing
equipment
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BENEFITS OF GROUP TECHNOLOGY

6. Manufacturing: quality control

 Reduction in number of defects leading to reduced inspection effort

 Reduced scrap generation
 Better output quality
 Increased accountability of operators and supervisors responsible
for quality production, making it easier to implement total quality
control concepts.
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BENEFITS OF GROUP
TECHNOLOGY

7. Purchasing

 Coding of purchased part leading to

standardized rules for purchasing
 Economies in purchasing possible because of
accurate knowledge of raw material
requirements
 Reduced number of part and raw materials
 Simplified vendor evaluation procedures
leading to just-in-time purchasing
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BENEFITS OF GROUP
TECHNOLOGY
8. Customer service

 Accurate and faster cost estimates

 Efficient spare parts management, leading to better
customer service
 Lower lead times
THANKS