Group Technology & Cellular Manufacturing: Industrial Engineering Ft-Uns

Group Technology & Cellular
Manufacturing
Industrial Engineering
FT-UNS
Group Technology
•Group technology is a manufacturing
philosophy in which similar parts are
identified and grouped together to take
advantage of their similarities in design and
production.
•Similar parts are arranged into part families,
where each part family possesses similar
design and manufacturing characteristics.
• Group technology and cellular manufacturing are
applicable in a wide variety of manufacturing
situations.
• GT is most appropriately applied under the
following conditions:
• The plant currently uses traditional batch production and
a process type layout
this results in much material handling effort, high in-
process inventory,and long manufacturing lead times
• The parts can be grouped Into part families
This is a necessary condition, Each machine cell is
designed to produce a given part family, or limited
collection of part families,so it must be possible to group
parts made in the plant into families.
application of GT
•Identifying the part families
•Rearranging production machines into
machine cells
The benefits of group technology
• GT promotes standardization of tooling, fixturing. and

setups.
• Material handling is reduced because parts are moved
within a machine cell rather than within the entire factory.
• Process planning and production scheduling are simplified
• Setup times are reduced, resulting in lower manufacturing
lead times.
• Work-in-process is reduced.
• Worker satisfaction usually improves when workers
collaborate in a GT cell.
• Higher quality work is accomplished using group technology.
Cellular Manufacturing
• Cellular manufacturing is grouping the production
equipment into machine cells, where each cell
specializes in the production of a part family.
Part Families
• Apart family is a collection of parts that are similar
either because of geometric shape and size or because
similar processing steps are required in their
manufacture.
• Figures 15.1 and 15.2 show two different part families.
• The two parts in Figure 15.1 are very similar in terms
of geometric design, but quite different in terms of
manufacturing because of differences in tolerances,
production quantities, and material.
lanjutan
• The ten parts shown in Figure 15.2 constitute a part
family in manufacturing, but their different
geometries make them appear quite different from a
design viewpoint.
• One of the important manufacturing advantages of
grouping workparts into families can be explained
with reference to Figures 15.3 and 15.4.
• Figure 15.3 shows a process type plant layout for
batch production in a machine shop.
• There is a lathe department, milling machine
department, drill press department, and so all. To
machine a given part, the workpiece must be
transported between departments, with perhaps
the same department being visited several times.
• This results in a significant amount of material
handling, large in-process inventory, many machine
setups, long manufacturing lead times, and high
cost.
• Figure 15.4 shows a production shop of equivalent
capacity, but the machines are arranged into cells.
• Each cell is organized to specialize in the production
of a particular part family.
• Advantages of reduced workpiece handling yield
lower setup times, fewer setups (in some cases, no
setup
changes are necessary), less in-process inventory,
and shorter lead times.
Part Classification and Coding
• In parts classification and coding, similarities among
parts are identified, and these similarities are
related in a coding system.
• Two categories of part similarities can be
distinguished:
(1) design attributes, which are concerned with part
characteristics such as geometry, size, and material.
(2) manufacturing attributes, which consider the
sequence of processing steps required to make a
part.
Reasons for using a coding scheme include:
• Design retrieval
• Automated process planning
• Machine cell design
Composite Part Concept
• a composite part for a given family, which includes

all of the design and manufacturing attributes of
the family.
• In general, an individual part in the family will have
some of the features that characterize the family
but not all of them.
Machine Cell Design
• single machine cell (type I M)
• group machine cell with manual handling (type n M
generally, type III M less common)
• group machine cell with semi-integrated handling
(type II M generally, type III M less common)
• flexibie manufacturing cell or flexible manufacturing
system (type II A generally, type III A less common)
U-Shape machine layout
In line layout & loop layout
Rectangular layout
Mixed model production system
Application Considerations in
Group Technology
•Manufacturing Applications
•Product Design Applications
Cellular Manufacturing
• Cellular manufacturing is an application of group
technology in which dissimilar machines or
processes have been aggregated into cells,
• dedicated to the production of a part or product
family or a limited group of families.
• The typical objectives in cellular manufacturing are
similar to those of group technology :
• To shorten manufacturing lead times, by reducing setup,
workpart handling, waiting times, and batch sizes.
• To reduce work-in-process inventory.
Smaller batch sizes and shorter lead times reduce work-
in-process.
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• To improve quality.
This is accomplished by allowing each cell to specialize
in producing a smaller number of different parts. This
reduces process variations.
• 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 parts are simply
scheduled through the cell.
• To reduce setup times.
CMS and Group Technology (GT)
• CMS layout are based on recognizing similarities in products
– similarities in geometry, size, materials and processing
requirements
• This similar products are collected – “Grouped” instead of
being treated as individuals
• Leads to product families that visit similar equipment and
populate their ‘cells’ production schedule
• Simpler setups like in a Job shop can follow and the workers
become multifunctional and responsible for all aspects of a
product – and its quality
• Cells can be scheduled to produce synchronously bringing
the various sub-assemblies in as needed at final assembly
with greater variety built in
Building the
FACTORY
With A
FUTURE
NOTE: Step 1 is CMS – a fundamental action in LEAN MFG’ing

Benefits of GT and CMS (Companies Reporting):
• 52% Report reduction in new part design

• 10% Report reduction in # of new drawings thru
standardization
• 30% Report reduction in new shop drawings
• 60% Report reduction in IE time
• 20% Report reduction in floor space
• 45% Report reduced scrap
• 80% Report reduced production and quality costs
• 69% Report reduced set-up time (cost)
Note: ‘Reported’ by companies in a survey of adopters of GT

Benefits of GT and CMS (Companies Reporting):
• 70% Report reduced throughput time (even more

report better predictability of delivery)
• 82% Report reduced numbers of overdue orders
• 42% Report reduced raw-materials inventory
• 62% Report reduced WIP
• 60% Report reduced finished goods inventory
• 33% Report increased employee output/time unit
(productivity improvement)
Clustering Techniques: the Fundamental
Issue in Cell Development
• We cluster parts to build part families
• Part Families visit cells
• Part Families share set-up ideas and equipment (Family
Fixtures)
• Part Families follow the same (or similar) process routing
• These are the ideas and activities that offer reported
benefits
Clustering Techniques: the Fundamental
Issue in Cell Development
•We cluster Machines to build cells:
• Cells lead to Flow Mathematics
• Cells contain all equipment needed to produce a
part family
• Cells allow development of Multi-functional
workers
• Cells hold work teams responsible for production
and quality “They Empower” the workers
• Empowered to set internal schedules
• Empowered to assign tasks
• Empowered to train and rotate jobs
• Etc, etc, etc
Building the CMS Facility
Before
Clustering
After
Clustering
Survey of Industry Practice
Batch production
Cellular manufacturing

Group Technology & Cellular Manufacturing: Industrial Engineering Ft-Uns

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Group Technology & Cellular

• GT promotes standardization of tooling, fixturing. and

• a composite part for a given family, which includes

NOTE: Step 1 is CMS – a fundamental action in LEAN MFG’ing

• 52% Report reduction in new part design

Note: ‘Reported’ by companies in a survey of adopters of GT

• 70% Report reduced throughput time (even more

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