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Manufacturing
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CRC Press
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Publisher’s Message IX
Chapter 1. An Introduction to
Cellular Manufacturing
Chapter Overview 1
What Is Cellular Manufacturing? 2
One-Piece Flow 3
High-Variety Production 5
Understanding Processes and Operations 6
Processes 6
Operations 7
Benefits of Cellular Manufacturing 8
How It Helps Companies 8
How It Helps You 9
In Conclusion 10
Summary 10
Reflections 11
CONTENTS
Acknowledgments
The development of Cellular Manufacturing has been a team
effort. Productivity Consulting Group members Frank Hammitt
and Richard Niedermeier served as content advisors. Cover com
position was by Shad Lindo and cover illustration by Gary
Ragaglia of The Vision Group. Lorraine Millard managed the
prepress production and manufacturing, with editorial assistance
from Pauline Sullivan. Page composition and additional design
was done by William H. Brunson Typography Services. Graphic
illustrations were created by Lee Smith and cartoon illustrations
were created by Hannah Bonner.
Finally, the Productivity staff wishes to acknowledge the good
work of the many people who are in the process of implementing
cellular manufacturing in their own organizations. We welcome
your feedback about this book, as well as input about how we can
continue to serve you in your implementation efforts.
Steven Ott
President
Karen Jones
Productivity Development Team
■ Getting Started
BACKGROUND
What This Book Is Based On
This book is about an approach to arranging the workplace for
processing items with minimal waste and delay. The methods and
goals discussed here are closely related to the lean manufacturing
system developed at Toyota Motor Company. Since 1979,
Productivity, Inc. has brought information about these approach
es to the United States through publications, events, training, and
consulting. Today, top companies around the world are applying
lean manufacturing principles to sustain their competitive edge.
Cellular Manufacturing draws on a wide variety of Productivity’s
resources. Its aim is to present the main concepts and techniques
of cellular manufacturing and one-piece flow in a simple, illus
trated format that is easy to read and understand.
GETTING STARTED
BACKGROUND
Two Ways to Use This Book
There are at least two ways to use this book:
1. As the reading material for a learning group or study group process
within your company.
2. For learning on your own.
BACKGROUND
Background
Information Sets the stage for what comes next
CHAPTER OVERVIEW
In Conclusion
Summary
Reflections
CHAPTER 1
Type Examples
One-Piece Flow
One-piece flow is the state that exists when products move
Key Term
through a manufacturing process one unit at a time, at a rate
determined by the needs of the customer (see Figure 1-2).
The opposite of one-piece flow is large-lot production. Although
Key Term many companies produce goods in large lots or batches, that
approach to production builds delays into the process. No items
can move on to the next process until all the items in the lot have
been processed. The larger the lot, the longer the items sit and
wait between processes.
CHAPTER 1
High-Variety Production
In the early days of industry, a company could produce one type
of product and customers would buy it, even if it wasn’t exactly
what they would have liked. Today, however, customers expect
variety and even customization, as well as specific quantities deliv
ered at a specific time. If your company isn’t flexible enough to
serve their needs, they will go to your competitor.
Cellular manufacturing offers companies the flexibility to give cus
Key Poi nt
tomers the variety they want (see Figure 1-4). It does this by group
ing similar products into families that can be processed on the
same equipment in the same sequence. It also encourages compa
nies to shorten the time required for changeover between prod
ucts. This eliminates a major reason for making products in large
lots —that changeovers take too long to change the product type
frequently.
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
®What is the size of a typical processing lot or batch in your
work area?
• How many different types of products does your work area
produce in a typical week? in a typical day?
CHAPTER 1
Steps of a Process
Storage/
raw materials or Operations
components * Essential operations:
Transport the actual value-adding
work on the materials
Transformation
Other operations:
Storage/waiting setup, transport,
for a process
inspection
Transport
Inspection
Storage
Processes
A process is a continuous flow through which raw materials are
Key Term
converted to finished products in a series of operations. The focus
is the path of the materials as they are transformed into something
to sell.
Manufacturing processes have four basic types of steps or phases;
• Transformation: assembly, disassembly, alteration of shape or quality
Key Points
• Inspection: comparison with a standard
• Transport: change of location
• Storage: a waiting period when nothing else is happening
Materials and parts often go through several of these steps during
a manufacturing process; the left side of Figure 1-5 shows a typi
cal sequence of process steps. Notice that only the transformation
Key Point
step adds value to the product.
AN I N T R O D U C T I O N TO C E L L U L A R M A N U F A C T U R I N G
Operations
In contrast to a process, which focuses on flow, an operation
focuses on action. An operation is any action performed by work-
ers or machines on the raw materials, work-in-process, or finished
products. The right side of Figure 1-5 gives examples of manufac
turing operations.
Since operations involve actions, operational improvements focus
on how specific actions are carried out. Operation improvement
approaches include studying the motions required for a specific
action, adjusting the height or angle of a work surface for easier
use, and so on.
To improve production for lean manufacturing, it is not enough to
p„i„, improve operations. Companies must also improve their processes.
Improving a process involves streamlining the flow of materials to
minimize obstacles and wastes such as
• Time spent in non-value-adding steps such as waiting or transport
• Downtime caused by changeover and adjustments
• Distance materials or WIP must travel between transformation steps
• The need for inspection, or for reworking materials
The cellular manufacturing approach works on improving the
Key Point proccss as well as specific operations.
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
• What kind of processes happen in your work area?
• What kind of operations do you perform in your daily work?
CHAPTER 1
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
• Based on what you have learned, can you see how cellular manu
facturing might benefit your company? If so, how?
®Can you see how it might benefit you? If so, how?
CELLULAR MANUFACTURING
SUMMARY
Cellular manufacturing is a lean manufaeturing approaeh that
helps eompanies build a variety of produets for their eustomers
with as little waste as possible. In eellular manufaeturing, equip
ment and workstations are arranged in a sequenee that supports
a smooth flow of materials and eomponents through the proeess,
with minimal transport or delay. Cellular manufaeturing is a
major building bloek of lean manufaeturing.
A manufaeturing eell eonsists of the people and the maehines or
workstations required for performing the steps in a proeess, with
the maehines arranged in the proeessing sequenee. Arranging
people and equipment into eells helps eompanies aehieve one-
piece flow and high-variety production.
One-piece flow is the state that exists when products move
through a manufacturing process one unit at a time, at a rate
determined by the needs of the customer. Operating so that
products flow one piece at a time allows the company to deliver
products to customers quicker, reduces storage and transport
requirements, lowers the risk of damage, and exposes other
problems to address.
Cellular manufacturing offers companies the flexibility to give
customers the variety they want. It allows variety by grouping
similar products into families that can be processed on the same
equipment. It also encourages companies to shorten changeover
time so product types can be changed more frequently.
Converting a factory to cellular manufacturing means eliminat
ing waste from processes as well as from operations. A process is
a continuous flow in which raw materials are converted to fin
ished products in a series of operations. The focus of a process
is the path of the materials as they are transformed into some
thing to sell. An operation is any action performed by workers or
machines on the raw materials, work-in-process, or finished
products.
10
AN I N T R O D U C T I O N T O C E L L U L A R M A N U F A C T U R I N G
REFLECTIONS
Now that you have corapleted this chapter, take five minutes
to think about these questions and to write down your
answers:: ', ,
; • What did you learn from reading this chapter that stands
out as particularly useful or interesting?
• Do you have any questions about the topics presented in
this chapter? If so, what are they?
• What additional information do you need to fully under
stand the ideas presented in thls^chapter?
11
Chapter 2
Working in a
Manufacturing Cell
CHAPTER OVERVIEW
14
W O R K I N G IN A M A N U F A C T U R I N G C E L L
TAKE FIVE
15
CHAPTER 2
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
» Do operators at your company run different kinds of machines?
If not, what would need to happen to make this possible?
® Do operators at your company run more than one machine?
If not, what would need to happen to make this possible?
16
W O R K I N G IN A M A N U F A C T U R I N G C E L L
TAKE F I V E
Take five minutes to think about these questions and to write
down your answers:
* Do you think the equipment in your area is better suited to
large-lot production or to cellular manufacturing for one-piece
flow? Why?
17
CHAPTER 2
@ S T O P FO R
AB N O KM A LITieS
AND SOUND
ALARM
■ STOP AFTER
ONE CYCLE
m UNLOAD AFTER
PROCESSING
m RUN AT A
C O N S T A N T SPEED
18
W O R K I N G IN A M A N U F A C T U R I N G C E L L
TAKE FIVE
19
CELLULAR MANUFACTURING
20
W O R K I N G IN A M A N U F A C T U R I N G C E L L
REFLECTIONS
Now that you; have completed this chapter^take five minutes
to think about:these questions and to write down your
yanswers:'
• What did: you learn from reading this ehapter that stands
21
Chapter 3
Basic Elements of Cell Design
CHAPTER OVERVIEW
In Conclusion
Summary
Reflections
CHAPTER 3
Cumulative
percentage
'"This chapter is longer than the other ehapters. You may want to read it in seetions; for
example, you might read the text about one of the phases, then pause for refleetion
and group diseussion.
24
B A S I C E L E M E N T S OF C E L L D E S I G N
100
90
80
70
60
Cumulative
50
percentage
40
30
20
10
0
Production Resources
In addition to reviewing the product mix, the team gathers base
line information about production resources, such as
• shifts per day
• hours per shift; break time
• work days per month
• employee to operation ratio
• monthly product volume requirements from customers
• approach for assigning work
• finished goods inventory turns per month
TAKE FIVE
25
CHAPTER 3
Processes
1 2 3 4 4A 5
Part Rough Outside
code cut Cut Mill Drill diameter Gauge
A KS/ rot W
.A®;.
C
......
G W
E s) \S)
F v,).; ■■■TaV' ■ io- ■/Ts- ■
A process route analysis table like the one in Figure 3-3 helps the
team identify processing similarities between different products.
This enables them to identify groups of products that could be
made in a cell, using the same sequence of machines. These
groups are called product families. If the company makes low
Key Term volumes of many product types rather than high volumes of a few
types, process route analysis is especially important for helping
the team choose a process to start with.
Key Point
26
B A S I C E L E M E N T S OF C E L L D E S I G N
w
3
2
-
I iA 4
II
12345pack:; Rl I 3
|23454Apadk:R2 i o
4A 6
4
Quality Safety Standard work # of pieces TAKT Time Net Time Operator
Rl @48 feet
o
Check Precaution in process of Std. WIP Number
R2 @72 feet
576 Sq.Ft ♦ + +60 17
Process Mapping
Next, the team draws a process map, which shows the current
Key Term equipment layout and the path the product takes through the
process. This map is often drawn on a Standard Work Sheet (see
Figure 3-4). The map also shows worker positions, WIP storage
points, quality checkpoints, and safety precautions. In addition,
the team records
• The distance the product must travel during processing
• The quantity of work-in-process in the process at a given time
• The number of people currently required to run the process
The team invites discussion with employees on the shop floor to
learn about any special conditions that have not been document
ed. Through these steps it develops a thorough understanding of
the basic elements of the current production process.
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
e Does your work area use the same machines to make different
types of products?
®Would a map of your current equipment layout show a short, effi
cient path or one that zigzags around?
27
CHAPTER 3
Component Task 1 2 3: 4 5 6 7: 8 9 10 11
'Rem/aside c
Unload/aside p a rt
&ef/load part
¿Tef / replai
Set fim er/sfa rf
Assem/aside part
W aif (mach, cycle)
28
B A S I C E L E M E N T S OF C E L L D E S I G N
1 ■ ■
= Value-adding operation time (stamp, weld, paint, finish, assemble)
95% HVA
TAKE F I V E
Take five minutes to think about these questions and to write
down your answers:
• What are some activities in your processing cycle other than the
actual value-adding work?
• Do you think your process’s value-added ratio is low or high?
Why?
29
co Process Capacity Table
Rev Date: H /Z5 Revision #:_ Page _ . of _
o Line Current Output/
Mgr. Spvr. Team Process Part No: 68 1 H 5 /6 Name /Person/Day
Capacity Workers up to
Max. output
Table Part Name: R I / R Z
daily needed
Machine Walk Base Time Non-Cyclic Tasks Total Daily
Operation Name No. Time
Remarks
Machine Total Time/Pc Time Capacity
Cuf ZO (8 ) Z8 Z8 985 R e m o v e g u a rd s
R ack 18 18 18 1533 00
N o te : R a r t s a r e
a sse m b le d in t e r n a l to
th e m a c h in e c y cle .
M a c h in e tim e in b r a c k e ts
in d ic a te s o p e r a t o r w a i t -
Total tim e, n o t m a c h in e c y c le
tim e.
Grand
116 (H3) 159 159
Total
Note: All times in seconds. Revise sheet following every improvement and state revision in remarks column.
B A S I C E L E M E N T S OF C E L L D E S I G N
31
0
CO
p Page _ [ __ of__L Standard Work Combination Sheet Operator:
w
SZ5T Effective Quantity Manual _
Q. Part no. 6 81H 5/6 Operation H/Z5 500
Ü 3 date per shift Automatic
Q. Walking nAAAAA^
Process TAKT Time 55 se con d s
'R l/ 'R Z / A a c h in e ì CeLL Waiting ^
name (Gap) (3 1) se con d s
5‘ Z U n lo a d /a s id e p a r t 3
o
3 O e t / io a d p a r t 3 X
>
co H S e t t im e r / s t a r t m a ch Z 15
“0
hO
5 A s s e m / a s id e p a r t H XI
CO
6 W a it on m a c h c y c le (ID
5° 10° 15° 20° 25° 30° 35° 40° 45° 50° 55° 60° 65° 70° 75° 80° 85° 90° 95°
Totals ZH 15 —
B A S I C E L E M E N T S OF C E L L D E S I G N
Number of people
Total WIP
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
®Which operations have more manuai time than machine time?
• Which operations tend to involve a lot of walking or searching for
things?
33
CHAPTER 3
c A
L P *
///
H ETH O DS M ACHINES
M ATERIALS PEOPLE
Methods
34
B A S I C E L E M E N T S OF C E L L D E S I G N
Machines
Materials
People
TAKE FIVE
35
CHAPTER 3
36
BASIC ELEMENTS OF C E L L D E S I G N
® p Oo 5 o
12345Pack: R1 Quality Safety Standard work # of pieces TAKT Time Net Time Operator
Check Precaution in process of Std. WIP Number
o + • 8 1
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
• Who should be involved in planning the new process layout? In
moving the equipment? In documenting the new procedures and
testing them out?
37
CHAPTER 3
I IV IP R O V E IV IE N T T I P S
38
B A S I C E L E M E N T S OF C E L L D E S I G N
TAKE FIVE
39
Figure 3-15. The Three Stages of SMED
’■ 'Named for the goal of eompleting ehangeover within a single-digit number of min
utes —9 minutes or fewer.
40
B A S I C E L E M E N T S OF C E L L D E S I G N
d^kevfive minutes to th
down your answers:
® How long does a typical changeover take in your work area?
® Can you list the changeover steps that could take place while the
machine is still running?
41
CHAPTER 3
42
B A S I C E L E M E N T S OF C E L L D E S I G N
TAKE F I V E
Take five minutes to think about these questions and to write
down your answers:
* What kinds of actions or conditions can cause defects in your
process? Can you think of ways to catch these conditions before
defects are made?
43
CHAPTER 3
BU MAS A co m prehen
'POINT I
A iM S A T G E T T IN G
USE
T H E H O S T E FF E C T IV E
OP E Q U IP H E H T .
2SYSTEM.
s iv eLO SS- preven t ION
D E F IN IT IO N
OF
TPM
U SE S T E A M - b a s e d
3 B R IN G S TOGETHER
PEOPLE FROM ALL
DEPARTMENTS CONCERHEt)
A REOUIRES THE SUPPORT
“ ANt> COOPERATION OF
EVERV'ONE PROM TOP
5 ACTiV m E S AIMED AT
PLANTVNDE GOALS OF
W/TH EQUIFMENT. m a n a g e r s T o SHOPFLÛOR ZERO LO SSES.
EM PLOYEES,
TAKE F I V E
Take five minutes to think about these questions and to write
down your answers:
» Are there machines in your work area that tend to fail or have
minor stoppages? What is the usual response when one of these
events happens?
44
B A S I C E L E M E N T S OF C E L L D E S I G N
- : :
SUMMARY
The conversion from an operation-based factory layout to cell
manufacturing has three basic phases:
• Understanding the current conditions
• Converting to a process-based layout
• Continuously improving the process
Phase 1, understanding the current conditions on the shop
floor, gives the team involved in the cell conversion a baseline
for measuring improvement. The team collects data such as
the product mix (using PQ analysis) and resources available
for production. The team also documents the layout and flow
of the current process, using process route analysis to deter
mine product families and drawing a process map on a
Standard Work Sheet.
Next the team times the process, recording the time for the steps
in one cycle of each machine in the process. The team uses the
cycle times for the operations in the process to determine a sam
ple lead time and value-added ratio for the total process. It then
uses a Process Capacity Table to calculate how many units each
individual operation can produce in a given time.
For the Process Capacity Table the team determines the takt
time for the process. Takt time is the rate at which each product
needs to be completed to meet customer requirements. It is cal
culated by dividing the daily work time by the daily required
quantity. Takt time, expressed in seconds per unit, becomes the
beat or pulse of the factory.
The final step in understanding the current conditions is cre
ation of a Standard Work Combination Sheet for each operation
in the process. This sheet is a graphic display of the time spent
in manual work, machine work, and walking for each step in a
particular operation. The team indicates the takt time on this
graph to show when the actual cycle time needs to be shortened
to match demand.
45
CELLULAR MANUFACTURING
46
B A S I C E L E M E N T S OF C E L L D E S I G N
REFLECTIONS
47
Chapter 4
Teamwork Tools for
Cellular Manufacturing
CHAPTER OVERVIEW
Working in Teams
Standardizing Workplace Conditions through 5S
Using Visual Management for Production
Controi and Safety
Performing Autonomous Maintenance Activities
Using Activity Boards and One-Point Lessons
In Conclusion
Summary
Reflections
CHAPTER 4
Working in Teams
The success of cellular manufacturing depends on teamwork. In
a cell, people often work together in new ways. For example, in
large-lot manufacturing, an operator might run just one type of
machine, with the goal of producing a specified output quantity.
In a cell, however, several different operations are combined in a
Key P o i n t sequence, and the main job of the people working in the cell is to
maintain a smooth flow through all the operations. This requires
people to coordinate their work in the cell. Employees working
in cells often learn several operations so they can proactively
keep the work flowing.
Teamwork is also important for improvement activities. A group of
Key P o i n t employees has more creative potential and energy than any person
working on a problem alone. The next several pages introduce
some team-based improvement approaches you may use in a
cellular manufacturing situation.
Sort: The team begins by sorting out and removing items not
Key T e r ms
needed in the work area. Teams often use the Red-Tag technique
to identify unneeded items and manage their disposition.
50
T E A M W O R K T O O L S FOR C E L L U L A R M A N U F A C T U R I N G
TAKE FIVE
51
CHAPTER 4
52
T E A M W O R K T O O L S FOR C E L L U L A R M A N U F A C T U R I N G
TAKE FIVE
53
CHAPTER 4
54
T E A M W O R K T O O L S FOR C E L L U L A R M A N U F A C T U R I N G
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
®Who performs basic cleaning and maintenance on the equipment
in your work area?
* Do you think autonomous maintenance activities would reduce
unplanned downtime in your company? Why or why not?
55
CHAPTER 4
Activity Board
Leader Members,
Results
Overall equipm ent effectiveness
Line 3
N -
month month month
Effects
A ctions Standardization
» g a
C Z ] l i S i Remaining issues and
1 1
i.... Z.......1
future plans
r ’" ~
d Z ]
CZZZZJ
1--------1 ^1
Ililii
.i
10 20 30
56
T E A M W O R K T O O L S FOR C E L L U L A R M A N U F A C T U R I N G
T AKE F I V E
Take five minutes to think about these questions and to write
down your answers:
• What kinds of information would be useful to display on an
activity board in your work area?
• What topic would you choose for a one-point lesson for your
work area?
57
CHAPTER 4
One-Point Lesson
2 Put the new machine tool into a spare holder cartridge until it clicks. Be sure
the line on the side of the tool aligns with the line on the cartridge.
When the current product run ends, take the machine offline and remove the
0 old cartridge.
4 Wipe off the tool stem on the machine, using a clean rag, then click the new
Click! cartridge into place.
6 Remove the old tool from its cartridge. Put the tool in the recycle bin. Check
Check! the cartridge for damage. If the cartridge is undamaged, store it for the next
changeover.
58
T E A M W O R K T O O L S FOR C E L L U L A R M A N U F A C T U R I N G
59
CELLULAR MANUFACTURING
60
T E A M W O R K T O O L S FOR C E L L U L A R M A N U F A C T U R I N G
REFLECTiONS
Now that you have completed this chapter, take five minutes
to think about these questions and to write down your
answers:
• What did you learn from reading this chapter that stands
out as particularly useful or interesting?
• Do you have any questions about the topics presented in
this chapter? If so, what are they?
• What additional information do you need to fully under
stand the ideas presented in this chapter?
61
Chapter 5
Reflections and Conclusions
CHAPTER OVERVIEW
64
R E F L E C T I O N S A ND C O N C L U S I O N S
Conclusions
Cellular manufacturing is more than a series of techniques. It is a
fundamental approach to improving the manufacturing process.
We hope this book has given you a taste of how and why this
approach can be helpful and effective for you in your work.
65
CHAPTER 5
66
R E F L E C T I O N S A ND C O N C L U S I O N S
67
CHAPTER 5
Quick Changeover
Newsletters
Lean Manufacturing Report—News and case studies on how com
panies are implementing lean manufacturing philosophy and spe
cific techniques such as cell design and total productive mainte
nance. For subscription information, call 1-800-394-6868.
Website
Visit our web pages at www. productivityinc. com to learn more
about Productivity’s products and services related to cellular
manufacturing.
68