CELLULAR MANUFACTURING

Cellular manufacturing is an application of group technology in manufacturing in which all or a portion of a firms manufacturing system has been converted into cells.

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CELLULAR MANUFACTURING
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
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The primary objectives in implementing a cellular manufacturing system are To reduce: 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
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 Manufacturing cells are sociological units: tendency to teamwork - motivation for process improvements more often arises naturally Manufacturing cells are natural candidates for just-in-time (JIT) implementation. Design of cellular manufacturing system is a complex exercise with broad implications for an organization
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Structural issues include:

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
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CELL FORMATION APPROACHES

Machine - Component Group Analysis: Machine - Component Group Analysis is based on production flow analysis

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EXAMPLE 1
A simple case of 4 machines and 6 parts
Components Machines 1 2 3 4 5 6

M1
M2 M3 1

1
1 1

1
1 1

1
1

M4
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1
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Components Machines M1 2 1 4 1 6 1 1 3 5

M2
M3 M4

1
1 1 1 1 1 1

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EXAMPLE 2: A case of 5 machines and 10 parts.

Components Machines
M1 M2 M3 M4 M5 1 1 1 1 1 1 1 1 1 1 1

1
1

2
1 1

3
1 1

4
1 1

5
1

7
1

8
1

9
1 1

10
1 1

1 1 1 1 1

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Rank Order Clustering Algorithm (ROC)

A simple algorithm used to form machinepart groups.

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Step 1: Assign binary weight and calculate a decimal weight for each row and column using the following formulas:

Decimal weight for row

i =

m p=1 n

bip 2m-p b pj2n p

Decimal weight for column j =

p=1

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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.
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Binary weight 29 28 27 26 25 24 23 22 21 Components Machines

M1 M2 M3 M4 M5 1 1 1 1 1 1 1 1 1 1 1

20

1
1

2
1 1

3
1 1

4
1 1

5
1 1

7
1

8
1

9
1 1

10
1 1 1

Decimal equivalent

1007 451 568 455 1020

1 1 1 1

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Binary weight
29 28 27 26 25 24 23 22 21 20

Components
Binary weight Machines

1
1 1 1

2
1 1 1 1

3
1 1 1 1

4
1 1 1 1

5
1 1 1

6
1 1

7
1 1 1

8
1 1 1

10

24 23 22 21 20
Decimal equivalent 4/25/2013

M5 M1 M3 M4 M2

1 1 1

1 1 1 11
14

28 27 27 27 28 20 28 26 11
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Binary weight
29 28 27 26 25 24 23 22 21 20

Components
Binary weight Machines

1
1 1 1

5
1 1 1

7
1 1 1

2
1 1 1 1

3
1 1 1 1

4
1 1 1 1

8
1 1

6
1

10

Decimal equivalent

24 23 22 21 20
Decimal equivalent

M5 M1 M3 M4 M2

1020 1 1 1 1 1019 900 1 1 123 115

1 1

28 28 28 27 27 27 26 20 11 11

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Machine-Part Group Formation Solution Procedures 1. Production flow analysis (Burbidge, 1971) 2. Rank order clustering (King 1980) 3. Clustering Analysis Similarity Coefficients (Anderberg, 1973; McAuley, 1972; Seifoddini & Wolfe, 1986) 4. Graph Partitioning (See Kusiak and Chow (1988) for a literature survey)
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Manufacturing Cell Layout Once machine clusters are identified, one needs to decide the best machine layout toimplement. For a good cell layout one must consider: Technological considerations Streamlined material flow Hollier methods specifies the machine layout that maximizes the proportion of insequence moves within the cell.
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