Unit 2

GROUP TECHNOLOGY
AND
FLEXIBLE MANUFACTURING SYSTEMS

Group Technology Introduction, part families, parts

classification and coding system OPTIZ and MI CLASS
system. Production flow analysis, cellular manufacturing
advantages, disadvantages and applications. FMS Introduction,
workstations, scope, components, types, benefits, typical FMS
layout configuration, functions of FMS computer control System

Contents
Group Technology

Introduction
Part families

Visual method
Parts Classification and Coding system

OPTIZ system
MI CLASS system.

Production flow analysis

Cellular Manufacturing

Advantages
Disadvantages
Applications.

FMS

Introduction

Workstations
Scope
Components

Types
Benefits
Typical FMS layout configuration
Functions of FMS computer control System

Introductio
n

Batch manufacturing is the most common form

of production.

It is important to make batch manufacturing as efficient and

productive as possible.
It is necessary to integrate the design and manufacturing
function of a firm.

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

Introductio
n

GT is more appropriate under the following

conditions:
The plant currently uses traditional batch production
and a process type layout
High material handling effort
High in-process inventory
Long manufacturing lead times

The parts can be grouped into part families

This is necessary condition as, each machine cell is designed to produce
a given part family, or a limited collection of part families, so it must be
possible to group parts made in the plant into families.

Introductio
n

There are two major tasks that a company must

undertake when it implements group technology.
Identifying the part families
Reviewing all parts drawings and grouping the parts into
families is substantial and time consuming task.
Rearranging production machines into machine cells
It is time-consuming and costly to plan and accomplish this
rearrangement, and the machines are not producing during
the changeover

Introductio
n

Group technology offers substantial benefits to

companies that have perseverance to implement it.
GT promotes standardization of tooling, fixturing, and setups
Material handling is reduced because the distances within a
machine cell are much shorter than within the entire factory
Process planning and production scheduling are simplified
Setup times are reduced, resulting in lower manufacturing lead
times
Work-in-progress is reduced
Worker satisfaction usually improves when workers collaborate
in a GT cell
Higher quality work is accomplished using group technology

Introductio
n

Part
Famil
y

PART FAMILIES
A part family is a collection of parts that are similar either in
geometric shape and size or in the processing steps required in
their manufacture.
The parts within the family are different, but their similarities
are close enough to merit their inclusion as members of the part
family.

Introductio
n

Part
Famil
y

Parts grouped by geometric shape

Parts grouped by manufacturing processes

Introductio
n

Part
Famil
y

Process type Plant

Layout

1.
2.
3.
4.
5.

High material handling

Large in-process inventories
Many machine setups
Long manufacturing lead times
High cost

Part
Famil
y

Introductio
n

Group
technol
ogy
Plant
Layout

1.
2.
3.
4.
5.

Reduced workpiece handling

Lower setup times
Fewer setups
Less in-progress inventory
Shorter lead-times

Introductio
n

Part
Famil
y

The big problem in changing over to group technology

from a conventional production shop is the problem of
grouping the parts into families.

Three methods of identifying part

family:
1. Visual inspection
2. Part classification and coding schemes
3. Production flow analysis (PFA Chart)

Introductio
n

Part
Famil
y

Classification is done by looking at either the physical parts or their

photographs and arranging them into groups having similar features

Least accurate method but first successful method using

GT.

Introductio
n

Part
Famil
y

Classification and Coding of Parts

This is the most time-consuming of the three methods, it uses
the similarities among parts are identified and these
similarities are related in a coding system.
Classification means to sort similar parts into predetermined
groups based on appropriate attributes (shape, manufacturing
process, material, etc.)
A code is a combination of letters and numbers that are
assigned to parts for information processing

Introductio
n

Part
Famil
y

Classification and Coding of Parts

Reasons for using a coding scheme
Design Retrieval: A designer faced with the task of developing a new
part can use a design retrieval system to determine if a similar part already
exists.
Automated process planning: The part codes for a new part can be
used to search for process plans for existing parts with identical or similar
codes.
Machine cell design: The part codes can be used to design machine
cells capable of producing all members of a particular part family, using the
composite part concept.

Introductio
n

Part
Famil
y

Classification and Coding of Parts

Features of Parts Classification and Coding Systems
Principle functional areas of this systems falls under two
categories,
1. Design
2. Manufacturing
According to parts classification system falls into one of
three categories:
1. Systems based on part design attributes
2. Systems based on part manufacturing attributes
3. Systems based on both design and manufacturing
attributes

Introductio
n

Part
Famil
y

Introductio
n

Part
Famil
y

Classification and Coding of Parts

Three structures used in classification and coding schemes:
Hierarchical Structure: Also known as monocode, in which the
interpretation of each successive symbol depends on the value of the
preceding symbols.

Chain-type structure: Also known as a polycode, in which the

interpretation of each symbol in the sequence is always the same; it does
not depend on the value of preceding symbols

Mixed-mode structure: A hybrid of the two precious coding schemes

Introductio
n

Part
Famil
y

Classification and Coding of Parts

Hierarchical Structure
1
1
1

2
2

31

3
2

Introductio
n

Part
Famil
y

Classification and Coding of Parts

Chain-type Structure

1
2
3
.
.

1
2
3
.
.

Decision Tree Classification

OPITZ SYSTEM
12345 6789 ABCD
- Basic code consist of first 9 digits. This
convey both design and manufacturing
data.
-First 5 digit 12345 called form code
- Next 4 digit 6789 called
supplementary code
- Next 4 digit ABCD called secondary
code

A Simple Rotaional Part

MULTI CLASS SYSTEM

This developed by the organization
for industrial research.
This is relatively flexible.
This used for variety of diff types of
mfg product.
It uses a hierarchical or decision tree
coding structure.
Coding structure up to 30 digits.

MULTI CLASS SYSTEM

Digit
Function
0 code system prefix
1 main shape category
2,3 external and internal configuration
4 - machined secondary elements
5,6 Functional description
7-12 Dimensional data (length,diameter)
13-Tolerances
14,15 Material chemistry
16 Raw material shape
17- production quantity
18- machined element orientation

PRODUCTION FLOW ANALYSIS(PFA)

It does not use part classification and
coding system.
It does not use part drawing
It used to analyze the operation
sequence and machine routing.
PFA uses manufacturing data rather
than design data.
Dis adv: It provides no mechanism for
rationalizing the manufacturing
routings.

PFA PROCEDURE
1.
2.
3.
4.

DATA COLLECTION
SORTING OF PROCESS ROUTINGS.
PFA CHART
ANALYSIS

Part Family & Manufacturing Cell

Formation: General Procedure
1. Define the scope of the study including system boundaries
2. Identify the similarity attributes of interest
3. Simplify:
Group obviously similar parts into representative part-type
Group pieces of equipment that must stay together into
representative machine-type
4. Find process plans using part-types and machine types
found in the previous step
5. Determine the Part-Machine Incidence Matrix
based on the process plans found in the previous step
6. Find the best Product Families and Machine Cells using
clustering methods.

Manufacturing Cell Layout

Once machine clusters are identified, one
needs to decide the best machine layout
to implement.
For a good cell layout one must consider:
-Technological considerations
-Streamlined material flow
Hollier methods specifies the machine
layout that maximizes the proportion of
in-sequence moves within the cell.

Hollier Method
Develop the From-To Chart
Determine the From/To ratio for each
machine by dividing the From-sum
by the To-sum for each machine
Arrange the machines in order of
decreasing From/To ratios
Machines with high ratios are placed at
the beginning of the flow.
In the case of ties, place machines with
higher From values first.

Solve the problem using Hollier Method :

Suppose that four machines, 1,2,3 and 4, belong to a GT
machine cell. An analysis of 50 parts processed on these
machines has been summarized in From/To chart given.
Additional information is that 50 parts enter the machine
grouping at machine 3, 20 parts leave after processing at
machine 1, and 30 parts leave after machine 4. Determine the
most logical machine sequence using the Hollier method.
To
From

25

30

15

10

40

10

Summing the From trips and To trips for each machine yeilds
the From and To sums as given below. The From/To ratios
is listed in the last column on the right.
To
Fro
m/T
o
rati
o

Fro
m

Fro
m
Sums

25

30

0.6

30

15

45

1.0

10

40

50

10

10

0.2
5

Arranging the
machines
in order
descending
From/To ratio,
To
50
45
0 of 40
135
the machinesSum
in the cell would be sequenced as follows
s
3
214

GT LAYOUT
1.Single machine cell
2.Group machine cell with manual
handling
3.Group machine cell with semiintegrated handling
4.Flexible manufacturing
system(FMS).

GT Layout

Flexible Manufacturing Systems (FMS)

A highly automated GT machine cells,

consisting of a group of processing
workstations
(CNC
M/C
tools),
interconnected by an automated handling
and storage systems, controlled by a
distributed computer system.

Why it is called as FMS?

It has been identified that a manufacturing system
should possess the following three capabilities in
order to be flexible,
The ability to identify and distinguish among
different incoming part or product styles processed
by the system.
Quick changeover of the operating instructions.
Quick changeover of physical setup.

To qualify as being flexible?

A manufacturing system should satisfy several criteria. The
following four tests of flexibility in an automated
manufacturing system can define the flexibility of the system.
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, that is, changes in part mix and/or
production quantities?
Error recovery test can the system recover gracefully from
equipment malfunctions and breakdowns, so that production
is not completely disrupted?
New part test can new part designs be introduced into
existing product mix with relative ease?

A typical FMS possesses multiple automated

stations and is capable of variable routings among
stations.
Its flexibility allows it to operate as a mixed
model system.
An FMS integrates into one highly automated
manufacturing system which consists of many of
the concepts and technologies, including flexible
automation, distributed computer control,
automated material handling and storage, and
group technology.

FMS technology can be applied in production

situations as follows,

Plant either produces parts in batches or uses manned

GT cells, and management wants to automate.
It is impossible to group a portion of the parts made
in the plant into part families, whose similarities
permit them to be processed on the machines in the
FMS.
The parts or products made by the facility are in the
mid-volume, mid-variety production ranging from
5000 to 75000 parts per year. If production volume is
below this range, an FMS is likely to be an expensive
alternative.

Difference between installing a FMS technology and

implementing a manually operated machine cell are as
follows,

The FMS requires a significantly greater investment

because new equipment in installed, whereas the manually
operated machine cell might only require to rearrange the
existing equipment.

the potential benefits of FMS includes, increased machine

utilization, reduced factory floor space, greater
responsiveness to change, lower inventory and
manufacturing lead times and higher labor productivity.

- The machining process is the largest applied

area for FMS technology.
- Allowing for wide range of possible
applications beyond machining.
- Relies on the principle of Group Technology.
- Most suited for the mid-variety and midvolume.
- Designed to produce parts within a defined
range of part shapes, sizes and processes.

Increase in
variety
Job
Low vol.
Batch
High vol.
Batch
Line

Numerically Controlled
(N.C.) Machines
Group Technology
F.M.S.
Dedicated
Lines

Increase in volume

Types of Flexibility
Each FMS is designed for sp. application
(parts / processes).
Hence FMS is
Custom engineered and Unique.

Flexibility types:
Machine flexibility, Production flexibility,
Mix flexibility, Product flexibility,
Routing flexibility, Volume flexibility,
Expansion flexibility.

FMS Classification
FMS classifications,
According to the operations
(i) Processing operations
(ii) Assembly operations
According to Number of Machines:
(i) Single Machine cell ( 1CNC + Sto. Sys.)
(ii) FMC ( 2 / 3 W/s + Hldg. Sys. + L / UL)
(iii) FMS ( 4 / more W / S + Common Hldg
+ Dist. Control systems)

FMS Classification ( contd.)

According to LEVEL of Flexibility
a) Random order FMS
For more Variety of PART configurations and
Quantity.
b) Dedicated FMS
For limited variety of parts styles.

FMS Components
1) Workstations

2) Material Handling and Storage

Systems
3) Computer control Systems
4) People

Flexible Manufacturing System

Computer
control
room

Tools

Conveyor

Machine

Machine
Pallet

Load

Parts

Unload
Terminal

Finished
goods

FMS Layouts

Open Field FMS Layout

WORKSTATIONS
A system intended for doing a set / sequence of
operations depends upon the TYPE of WORK to be
accomplished by the system.
Types:
LOAD / UNLOAD stations:
Machining Stations:
CNC machining centers: Vertical, Horizontal

Other processing stations:

Assembly stations:

CNC machining centers:

Vertical centers,
Horizontal centers.
Horizontal centers possess the features that make it
compatible with FMS.
Such Features are:
ATC, ATS, Palletized WPs, APC,CNC and ability for DNC.
Machining centers are mainly for NON-Rotational Parts.

CNC machining centers (contd.)

For Rotational Parts:
Turning Module is available.

For multi tooth rotational operations:

Mill-Turns are used.

Milling Modules and Drilling Modules are

special purpose centers.
Milling module can be Vertical Spindle, Horizontal
spindle or Multi Spindle types.

Other Processing Stations

Sheet Metal operations

Press working operations
like Punching, Piercing,
Shearing, Forming and
Bending Operations.
Forging process
Welding unit,
Painting unit and etc.,

Other Processing Stations Contd.,

Assembly operations, ( Programmable part
placement machines)
Inspection processes
Other activities:
Cleaning ,
Palletizing and Central Coolant Delivery
systems etc.,)

Material Handling and Storage Systems

Functions:
- Random / Independent movement between
stations
- Handle a variety of parts
- Temporary storage
- Convenient access for loading and unloading
parts
- Compatible with computer control

Types of Handling systems

Primary systems & Secondary systems
Primary systems:
Movement from one place to other place
( conveyors, AGVs, etc.,)

Secondary systems:
Movement of parts within the same destination
[Loading and Unloading] ( Transfer devices and
APC etc.,)

62

FMS Layout Configurations

Computer control system functions

Control of each workstation
Distribution of control instructions to each workstation
Production control
Traffic control
Shuttle control
Work handling system monitoring
Tool control
System performance and monitoring
64

System Reports
Utilization reports
Production reports
Status reports
Tool reports

65

Human Resources
Availability
Uptime proportions
Reasons for downtime
Utilization
Each work stations
FMS for specified periods (days, weeks, months)
Production
Daily weekly quantities against production schedule
Tooling
Listing of tools at each work stations
Tool life status
Status
Line supervision
Current status of the system operating parameters

System Reports
Volume of work to be produced by the system
Variation in process routings
Physical characteristics of the workparts
Part families defined according to product commonality
FMS manpower requirements
Appropriate production volume range
Minimum number of machines/FMS: 4
Minimum normal tolerance on work in an FMS: +/- 0.05
67

Hierarchical control of an FMS

68