Cellular Manufacturing

Cellular manufacturing is an application of group technology in which dissimilar

machines or processes have been aggregated into cells, each of which is dedicated
to the production of a part or product family or a limited group of families.
Objectives of Cellular Manufacturing

• To shorten manufacturing lead times by reducing setup, work-part

handling, waiting times, and batch sizes.

• To reduce work-in-process inventory. Smaller batch sizes and shorter

lead times reduce work-in process.

• To improve quality. This is accomplished by allowing each cell to

specialize in producing a smaller number of different parts. This reduces
process variability.
• To simplify production scheduling. The similarity among parts in the
family reduces the complexity of production scheduling. Instead of
scheduling parts through a sequence of machines in a process-type shop
layout, the system simply schedules the parts through the cell.

• To reduce setup times

Two aspects of cellular manufacturing are considered in this section:
(1) the composite part concept

(2) machine cell design.

COMPOSITE PART CONCEPT
• It is based on the features of all the components
forming a group
• The various operations are required to complete group
of parts.
• Composite Part requires all the operations of the group.
• To produce any actual part of the group, operations are added or
deleted corresponding to the requirements of the part.

• This concept is then extended by setting up a machine cell.

• A composite part for a given family, which includes all of the design
and manufacturing attributes of the family.
Machine cell

• Design of the machine cell is critical in cellular manufacturing. The cell design
determines to a great degree the performance of the cell.

Types of Machine Cells.

(1) assembly cells, which produce families of subassemblies or products, or

(2) part cells, which process families of parts.

• Machine cells for part family production can be classified according to the
number of machines and the degree to which the material flow is mechanized
between machines.

Four common GT cell configurations are:

(1) single-machine cell

one machine plus supporting fixtures and tooling. This type of cell can be applied to
work parts whose attributes allow them to be made on one basic type of process,
such as turning or milling.
(2) group-machine cell with manual handling

an arrangement of more than one machine used collectively to produce one or more
part families, and there is no provision for mechanized parts movement between
machines in the cell.

(3) group-machine cell with semi-integrated handling uses a mechanized handling

system, such as a conveyor, to move parts between machines in the cell.
4) flexible manufacturing cell or flexible manufacturing system.

It is a fully integrated material handling system with automated processing stations.

The FMS is the most highly automated of the group technology machine cells.
Flexible Manufacturing System

Flexible manufacturing system (FMS) is a highly automated GT machine cell, consisting

of a group of processing workstations (usually CNC machine tools), interconnected by an
automated material handling and storage system, and controlled by a distributed computer
system.

The reason the FMS is called flexible is that it is capable of processing a variety of
different part styles simultaneously at the various workstations, and the mix of part styles
and quantities of production can be adjusted in response to changing demand patterns.
Tests of flexibility

To qualify as being flexible, an automated manufacturing system should satisfy the

following four tests of flexibility.

• Part variety test. Can the system process different part styles in a non batch mode?.

•Schedule change test. Can the system readily accept changes in production
schedule, and changes in either part mix or production quantity?

•Error recovery test. Can the system recover quickly from equipment breakdowns,
so that the production is not completely disrupted?

• New part test. Can new part designs be introduced into the existing product mix
with relative ease?
Types of FMS

Flexible manufacturing systems according to the number of machines in the system.

• Single machine cell

• Flexible manufacturing cell

• Flexible manufacturing system

Single machine cell (SMC)

• A single machine cell consists of one CNC machining centre combined with a
parts storage system for unattended operation.

• Completed parts are periodically unloaded from the parts storage unit, and raw
work parts are loaded into it.
Flexible manufacturing cell (FMC)

• consists of two or three processing workstations (typically CNC machining

centers or turning centers) plus a parts-handling system.

• The parts-handling system is connected to a load/unload station.

• The handling system usually includes a limited parts-storage capacity.

Flexible manufacturing system (FMS)

• (FMS) has four or more processing stations connected mechanically by a

common parts-handling system and electronically by a distributed computer
system.

• An important distinction between an FMS and an FMC is the number of

machines: an FMC has two or three machines, while an FMS has four or
more.

• There are usually other differences as well. One is that the FMS generally
includes non processing workstations that support production but do not
directly participate in it. These other stations include part/pallet washing
stations, inspection stations, and so on.
• Another difference is that the computer control system of an FMS is
generally more sophisticated, often including functions not always
found in a cell, such as diagnostics and tool monitoring.
Types of FMS based on level of flexibility

• Two categories of flexibility are discussed here:

• dedicated
• random-order.
Dedicated FMS

• A dedicated FMS is designed to produce a limited variety of part styles, and the
complete universe of parts to be made on the system is known in advance.

• The part family may be based on product commonality rather than geometric
similarity. The product design is considered stable, so the system can be designed
with a certain amount of process specialization to make the operations more
efficient.

• Instead of being general purpose, the machines can be designed for the specific
processes required to make the limited part family, thus increasing the production
rate of the system.
Random-order FMS
• A random-order FMS is more appropriate when the part family is large there are
substantial variations in part configurations, there will be new part designs
introduced into the system and engineering changes in parts currently produced,
the production schedule is subjected to change from day-to-day.
FMS/FMC components
• Workstations.
• Material handling and storage systems.
• Computer control system.
• People required to manage and operate the system
Workstations
Types of workstations typically found in an FMS are :

1. Load/Unload Stations.

2. Machining Stations.

3. Other processing Stations. (punching, shearing, welding, etc.)

4. Assembly Station.

5. Other Stations and Equipment. (Inspection, Vision etc)

Material handling and storage systems
• Primary handling system establishes the basic layout of the FMS and is responsible for
moving work parts between stations in the system (Conveyor).

• Secondary handling system consists of transfer devices, automatic pallet changing, and
similar mechanisms located at the workstations in the FMS.

• The function of the secondary handling system is to transfer work from the primary
system to the machine tool or other processing station and to position the parts with
sufficient accuracy and repeatability to perform the process or assembly operation.
Computer Control System
The FMS includes a distributed computer system that is interfaced to the
workstations, material handling system and other hardware components.

• A typical FMS computer system consists of a central computer and microcomputers.

• Microcomputers control the individual machines and other components.

•The central computer coordinates the activities of the components to achieve smooth
overall operation of the system.
Human resources
Human are needed to manage the operations of the FMS. Functions typically performed by human
includes:

• Loading raw work parts into the system

• Unloading finished parts (or assemblies) from the system

• Changing and setting tools

• Equipment maintenance and repair

• NC part programming in a machining system

• Programming and operation of the computer syste m.

FMS Layout

The material handling system establishes the FMS layout.

• in-line layout,

• loop layout,

• open field layout,

• robot-centered cell.
In-line layout
• In the in-line layout, the machines and handling system are arranged in a straight
line.

• In its simplest form, the parts progress from one workstation to the next in a well-
defined sequence with work always moving in one direction and no back-flow.
loop layout
• the workstations are organized in a loop that is served by a parts handling system
in the same shape.

• Parts usually flow in one direction around the loop with the capability to stop and
be transferred to any station.

• A secondary handling system is shown at each workstation to allow parts to move

around the loop without obstruction.
Open field layout

• The open field layout consists of multiple loops and branches, and
may include sidings as well.
Robot Centered Cell

• uses one or more robots as the material handling system.

• Industrial robots can be equipped with grippers that make them well suited for the
handling of rotational parts and

• robot-centered FMS layouts are often used to process cylindrical or disk-shaped

parts.
Computer Integrated Manufacturing

• Computer Integrated Manufacturing (CIM) encompasses the entire range of

product development and manufacturing activities with all the functions being
carried out with the help of dedicated software packages.

• The data required for various functions are passed from one application software
to another in a seamless manner. For example, the product data is created during
design. This data has to be transferred from the modelling software to
manufacturing software without any loss of data.
• CIM uses a common database wherever feasible and communication
technologies to integrate design, manufacturing and associated
business functions that combine the automated segments of a factory
or a manufacturing facility.

• CIM reduces the human component of manufacturing and thereby

relieves the process of its slow, expensive and error prone component
DEFINITION OF CIM
The Computer and Automated Systems Association of the Society of Manufacturing Engineers (CASA/SME)

defines CIM as the integration of total manufacturing enterprise by using integrated systems and data
communication coupled with new managerial philosophies that improve organizational and personnel
efficiency.

CIM is recognized as Islands of Automation. They are:

• CAD/CAM/CAE/GT

• Manufacturing Planning and Control.

• Factory Automation

• General Business Management

CIM HARDWARE AND CIM
SOFTWARE
CIM Hardware comprises the following:

I. Manufacturing equipments such as CNC machines or computerized work centres,

robotic work cells, DNC/FMS systems, work handling and tool handling devices,
storage devices, sensors, shop floor data collection devices, inspection machines etc.

II. Computers, controllers, CAD/CAM systems, workstations / terminals, data entry

terminals, bar code readers, RFID tags, printers, plotters and other peripheral
devices, modems, cables,connectors etc.
Major elements of a CIM system

Marketing:

• The need for a product is identified by the marketing division.

• The specifications of the product, the projection of manufacturing quantities and

the strategy for marketing the product are also decided by the marketing
department.

• Marketing also works out the manufacturing costs to assess the economic
viability of the product.
Product Design:

• The design department of the company establishes the initial database for
production of a proposed product.

• In a CIM system this is accomplished through activities such as geometric

modelling and computer aided design while considering the product requirements
and concepts generated by the creativity of the design engineer.
Planning:

• The planning department takes the database established by the design department
and enriches it with production data and information to produce a plan for the
production of the product.

• Planning involves several subsystems dealing with materials, facility, process,

tools, manpower, capacity, scheduling, outsourcing, assembly, inspection, logistics
etc.

• In a CIM system, this planning process should be constrained by the production

costs and by the production equipment and process capability, in order to generate
an optimized plan.
Purchase:

• The purchase departments is responsible for placing the purchase orders and
follow up, ensure quality in the production process of the vendor, receive the
items, arrange for inspection and supply the items to the stores or arrange timely
delivery depending on the production schedule for eventual supply to manufacture
and assembly.
Manufacturing Engineering:

• Manufacturing Engineering is the activity of carrying out the production of the

product, involving further enrichment of the database with performance data and
information about the production equipment and processes.

• In CIM, this requires activities like CNC programming, simulation and computer
aided scheduling of the production activity.

• This should include online dynamic scheduling and control based on the real time
performance of the equipment and processes to assure continuous production
activity.
Factory Automation Hardware:

• Factory automation equipment further enriches the database with equipment and
process data to carry out the production process.

• In CIM system this consists of computer controlled process machinery such as

CNC machine tools, flexible manufacturing systems (FMS), Computer controlled
robots, material handling systems, computer controlled assembly systems, flexibly
automated inspection systems and so on.
Warehousing:

• Warehousing is the function involving storage and retrieval of raw materials,

components, finished goods as well as shipment of items.

• In today’s complex outsourcing scenario and the need for just-in-time supply of
components and subsystems, logistics and supply chain management assume great
importance.
Finance:

• Finance deals with the resources pertaining to money.

• Planning of investment, working capital, and cash flow control, realization of

receipts, accounting and allocation of funds are the major tasks of the finance
departments.
• Information Management:

• Involves master production scheduling, database management, communication,

manufacturing systems integration and management information systems.
The Scope of CAD/CAM and CIM

• Computer integrated manufacturing includes all of the engineering

functions of CAD/CAM, but it also includes the firm’s business
functions that are related to manufacturing.

• The ideal CIM system applies computer and communications

technology to all of the operational functions and information
processing functions in manufacturing from order receipt, through
design and production, to product shipment.
Computerized elements of a CIM system

• The CIM concept is that all of the firm’s operations related to production are
incorporated in an integrated computer system to assist, augment, and automate
the operations.

• In this integrated computer system, the output of one activity serves as the input to
the next activity, through the chain of events that starts with the sales order and
culminates with shipment of the product.
• Customer orders are initially entered by the company’s sales force or directly by
the customer into a computerized order entry system.

• The orders contain the specifications describing the product.

• The specifications serve as the input to the product design department. New
products are designed on a CAD system.

• The components that comprise the product are designed, the bill of materials is
compiled, and assembly drawings are prepared.
• The output of the design department serves as the input to manufacturing
engineering, where process planning. tool design, and similar activities are
accomplished to prepare for production.

• Process planning is performed using CAPP. Tool and fixture design is done on a
CAD system, making use of the product model generated during product design.

• The output from manufacturing engineering provides the input to production

planning and control. where material requirements planning and scheduling are
performed using the computer system.

• Full implementation of CIM results in the automation of the information flow

through every aspect of the company’s organization.
Automated Assembly Systems
• The term automated assembly refers to mechanized and automated devices that perform various
assembly tasks in an assembly line or cell.

• An automated assembly system performs a sequence of automated assembly operations to combine

multiple components into a single entity.

• The single entity can be a final product or a subassembly in a larger product.

• In many cases, the assembled entity consists of a base part to which other components are attached.
The components are usually joined one at a time, so the assembly is completed progressively.
A typical automated assembly system consists of the following subsystems:

(1) one or more workstations at which the assembly steps are accomplished,

(2) parts feeding devices that deliver the individual components to the
workstation(s),

(3) a work handling system for the assembled entity.

System Configuration

• Automated assembly systems can be classified according to physical

configuration. The principal configurations, are

(a) in-line assembly machine,

(b) dial-type assembly machine,

(c) carousel assembly system, and

(d) single-station assembly machine.

In-line assembly machine

• It is a series of automatic workstations located along an in-line transfer system. It

is the assembly version of the machining transfer line.

• Synchronous and asynchronous transfer systems are the common means of

transporting base parts from station to station with the in-line configuration.
Dial type assembly machine

• In this type base parts are loaded onto fixtures or nests attached to the circular
dial.

• Components are added and/or joined to the base part at the various workstations
located around the periphery of the dial.

• The dial indexing machine operates with a synchronous or intermittent motion, in

which the cycle consists of the service time plus indexing time.
Carousel assembly system

• The carousel assembly system represents a hybrid between the circular work flow
of the dial-type assembly machine and the straight work flow of the in-line
system.

• The carousel configuration can be operated with continuous, synchronous, or

asynchronous transfer mechanisms to move the work around the carousel.

• Carousels with asynchronous transfer of work are often used in partially

automated assembly systems.
Single-station assembly machine

• assembly operations are performed on a base part at a single location.

• The typical operating cycle involves the placement of the base part at a stationary
position in the workstation, the addition of components to the base, and finally the
removal of the completed assembly from the station.

• An important application of single-station assembly is the component placement

machine.