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Group technology | Methods of form part families | Different code system - OPTIZ, MICLASS with examples | Production flow analysis 4.5 Group Technology Group technology is a manufacturing technique and philosophy to increase production efficiency by exploiting the underlying sameness of component shape, dimensions, process route, etc. Why Group Technology? Average lot size decreasing Part variety increasing Increased variety of materials with diverse properties Requirements for closer tolerances Benefits of Group Technology Reductions in Throughput time Set-up time Overdue orders Production floor space Raw material stocks In-process inventory Capital expenditures Tooling costs Engineering time and costs New parts design New shop drawings Total number of drawings Easier to justify automation Standardization in design Data retrieval Easier, more standardized process plans Increases in quality

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Fig 4.10 : (a) Production system types

Fig 4.10 : (b) Types of production and choice of process related to product quantity and volume

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4.6 Methods for Developing Part Families Group technology is begun by grouping parts into families based on their attributes. Usually, these attributes are based on geometric and/or production process characteristics. Geometric classification of families is normally based on size and shape, while production process classification is based on the type, sequence , and number of operations. The type of operation is determined by such things as the method of processing, the method of holding the part, the tooling, and the conditions of processing. For example, Fig 4.11 show families of parts grouped by geometric shape and by production process. The identification of a family of parts that has similarities permits the economies of scale normally associated with mass production to be applied to small-lot, batch production. Therefore, successful grouping of related parts into families is a key to implementation of the group technology philosophy.

Fig 4.11: (a) Parts grouped by geometric shape

Fig 4.11: (b) Parts grouped by manufacturing processes

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4.6 Three techniques to form part families 4.6.1 Tacit judgment or visual inspection This is a simple and crude method of examining and grouping parts and machines through the bare eye according to the judgment of an inspector. Classification of parts into families is simply made by looking at their shapes and these shapes are usually design features. 4.6.2 Production Flow Analysis Production flow analysis (PFA) is a method for identifying part families based on the sequence of operation and machine routing needed to produce the part. Since PFA uses manufacturing attributes rather than design attributes to identify and form part families, it can overcome two possible anomalies. First, parts whose basic geometries are quite different may have similar or identical process routings (Fig. 4.11b). Second, parts whose geometries are similar may requires different process routings (Fig. 4.11a). However, the disadvantages with this method of part family formation is that it accepts previously set routes sheets without consideration of its being logical or consistent, there is no mechanism for rationalizing the manufacturing routings. The procedure in Production flow analysis can be organized into the following steps. (a) Data collection The first step in PFA procedure is to decide on the scope of the study and to collect the necessary data. The scope defines the population of parts to be analyses. Once the population is defined, the minimum data needed in the analysis, the part number and the machine routing (operation sequence) for every part, is collected. These data can be obtained from the route sheets. Additional data, such as lot size, time standards, and annual production rate, might be useful for designing machine cells of the desired production capacity. (b) Sorting of process routings This is the second steps were parts are arrange into groups according to their similarity of their process routings. For large number of parts in the study, the only practical way to accomplish this step is to code the data collected in step 1 onto computer cards. A sorting procedure would be used on the cards to arrange them into Packs. A pack is a group of parts with identical process routings. (c) PFA chart The processes used for each pack are next displayed graphically on a PFA chart. It is merely a plot of the process code numbers for all the packs that have been determined. (d) Analysis This is the most subjective and difficult step in PFA, yet it is the curtail step in the procedure. The difficulty comes from the amount of information that must be processed accurately to
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facilitate the formation of manufacturing cells that are dedicated to specific-part family production.

Fig 4.12 (a): Component machine chart

Fig 4.12 (b): example of production flow analysis.

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Fig 4.13: Example of production flow analysis.

(Source: http://www.strategosinc.com/gt-production_flow_analysis.htm)

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Example : Lets consider 5 parts (n) and 6 machines (m) n = {101, 102, 103, 104, 105} m = {Drill , Drill , Mill , Mill , Vbore , Vbore }
1 2 1 2 1 2

{D , D , M , M , V , V }
1 2 1 2 1 2

Operation Routing Summary Part No. 101 102 103 104 105 Routing D1 -M1 - V1 D2 -M2- V1 D1 -M1 M 2 - V 2 - D2 V1 - M 1 - D1 Times (min) 9 - 12 - 14 5 - 11 - 14 7-9 8 - 12 - 5 7 - 10 - 12 Ave. Dem. 100 250 700 100 200

Create a PFA matrix, M

Rank order clustering

Step 1: Calculate the total column width for each column

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Step 2: If W is in ascending order, go to step 3; otherwise, rearrange the columns to make W fall
j j

in an ascending order.

Step 3: calculate the total row weight, w

Step 4: If w is in ascending order, stop. Otherwise, arrange rows to make W ascend.

i i

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Step 5: Stop and make Cells and Part families

Cell 1: {D1, M1, V1}, {103, 101, 105} Cell 2: {V2, D2, M2}, {102, 104} Part No. 101 102 103 104 105 Routing D1 -M1 - V1 D2 -M2- V1 D1 -M1 M 2 - V 2 - D2 V1 - M 1 - D1 Times (min) 9 - 12 - 14 5 - 11 - 14 7-9 8 - 12 - 5 7 - 10 - 12 Ave. Dem. 100 250 700 100 200
103

101 103

101

D1

M1

V1

102 105 105

104 102

D2

M2

V2

104

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4.6.3 Classification and Coding Classification of parts is the process of categorizing parts into groups, sometimes called families, according to a set of rules or principles. The objectives are to group together similar parts and to differentiate among dissimilar parts. Coding of a part is the process of assigning symbols to the part. These symbols should have meanings that reflect the attributes of the part, thereby facilitating analysis (information processing). Herein, grouping and classifying parts into family is made by examining and analyzing the design and/or manufacturing attributes of each parts. A large number of classification and coding systems have been developed for group technology applications, all of them can be grouped into three basic types: (a) Monocode (or hierarchical structure) In this type of code structure, each code number is qualified by the preceding digits (characters). Thus if the first digits define the type of material used, such as steel, the second digits will define a feature related to steel (like carbon constraint), and the next digit will define a feature related to the feature defined in the second digit and so on. A typical hierarchical code structure is shown in Fig 4.12(b). (b) Attribute or Polycode or Chain-type Structure In this type of structure, the interpretation of each symbol in the sequence is fixed and represents one feature. Thus, the value of any given digits (or position) within the code does not depend on the preceding digits. Another name of this type of symbol is polycode. The problem associated with polycode is that the code tends to be relatively long. On the other hand, the use of polycode allows for convenient identification of specific part attribute. This can be helpful in recognizing parts with similar processing requirements. A typical attribute code is illustrated in the table below. As we can see from the table, each digit and each value in the specific digit has a specific meaning. Thus, for example, the first digit may always describe external shape of the part, the second digit describe internal shape, the third digit describe there is internal hole, the fourth digit describe the type of hole and so on. For the example shown in Fig 4.12(a) the polycode is 22213. (c) Mixed Code Most of the commercial parts coding system in industries are a combination of the two pure structure (i.e. poly codes and mono codes). The hybrid is an attempt to achieve the best feature of both polycodes and monocodes. Hybrid codes are typically constructed as a series of short poly codes. Within each of these shorter chains, the digits are independent, but one or more of symbols in the complete code number are used to classify the part population into groups, as in the hierarchical structure. This hybrid coding seems to best serve the need of both design and production.

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Fig 4.14: (a) A spur gear

Fig 4.14: (b) hierarchical code for spur gear shown in Fig 4.12(a)

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Fig 4.14: (c) Attribute code example

Fig 4.14: (d) Hybrid code structure

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Fig 4.15: Example of casting coding and classification

(Source: http://www.strategosinc.com/gt-coding_classification.htm)

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4.7 Opitz coding and classification system This classification and coding system was developed by H. Opitz in 1970 at Aachen Technology University in West Germany. The coding system uses the following digital sequence: 123456789ABCD The basic code consists of nine digits that can be extended by additional four digits. The general interpretations of the nine digits are as indicated in Fig 4.16. The first five digits are called the form code and indicate the design or the general appearance of the part and hence assist in design retrieval. Later, 4 more digits were added to the coding scheme, in order to increase the manufacturing information of the specific work part. These last four digits are also called supplementary code. All four are integers, and respectively represent: Dimensions, Material, Original shape of raw stock, and Accuracy of the work part. The extra four digits, A, B, C, and D, called the secondary code, are used by the specific organization to include those characters that are specific to the organization.

Fig 4.16: OPITZ code structure Example 1: For the part design in Fig 4.17(a) define the "form code" using the Opitz system Digit 1: The total length of the part is 1.75, overall diameter 1.25, L/D = 1.4 (code 1) Digit 2: External shape - a rotational part that is stepped on both with one thread (code 5)
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Digit 3: Internal shape - a through hole (code 1) Digit 4: By examining the drawing of the part (code 0) Digit 5: No auxiliary holes and gear teeth (code 0) Code: 15100

Fig 4.17: (a) Example of OPITZ code for a rotational component Example 2: For the part design in Fig 4.17(b) define the "form code" using the Opitz system

Fig 4.17: (b) Example of OPITZ code for a mild steel forged round rod Digit 1: Digit 2: Digit 3: Digit 4: Digit 5: Digit 6: Digit 7: Digit 8: Digit 9: 1 (Rotational parts, 0.5<L/D<3.) 1 (External shape element, stepped to one end.) 1 (Internal Shape element, smooth or stepped to one end.) 0 (No surface machining.) 5 (Auxiliary holes, radial.) 2 (50 mm. < diameter <=100 mm.) 3 (material is mild steel.) 0 (Internal form: Round bar.) 2 (Accuracy in coding digit.)

Code: 111052302
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4.7 MICLASS System The name MICLASS stands for Metal Institute Classification System, and was developed by the Netherlands Organization for Applied Scientific Research (TNO) of Holland in 1969. Like Opitz classification system, MICLASS is also be made by using design and manufacturing attributes of the work part. The system was developed in such a way that to standardize a number of different design, manufacturing and management function. This will includes, standardization of engineering drawings, easy of retrieval drawings based on their classification code, standardize process routing, automate process planning, selection of parts for processing on a particular machine groups and machine tool investment analysis. The total number of digits used in MICLASS classification system may vary from 12 to 30 digits. The digits can be divided into two. The first twelve digits are a universal nature and can be applied to any work part. The other 18 digits which is called supplemental codes can be used for data that are specific to the particular company. Those supplemental digits provide a flexibility to accommodate broad applications. Such as lot size, cost data, and operation sequence. The design attributes used in the first twelve digits of MICLASS classification are as follows: 1st digit 2nd and 3rd digit 4th digit 5th and 6th digit 7th digit 8th digit 9th and 10th digit 11th and 12th digit 4.9 Types of layout Maine Shape Shape Element Position of Shape element Main Dimension Dimension Ratio Auxiliary Dimension Tolerance Code Material Code

Fig 4.18: (a) Product layout.

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Fig 4.18: (b) Functional layout.

Fig 4.18: (c) GT cell

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Fig 4.18:(d) GT flow line(Note: L: Lath; M: Milling Machine; G: Grinding Machine;

and D: Drilling Machine)

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