Industrial Work Group

Group Technology and Cellular Manufacturing

Ramiro Bonaque Rodrguez Jose Lus Gandia Forns

Toni Barber Pastor

Universitat Jaume I de Castell

Table of contents
1. Introduction 2. Parts classification and coding 3. Production flow analysis 4. Cellular manufacturing 5. Application considerations in group

technology
6. Quantitative analysis in cellular manufacturing

1. Introduction
Processes types for batch manufacturing
Process type plant layout
Turning Milling Assembly Drilling Shipping Receiving

Process type group technology

Machines are arranged by function.

Machines are arranged into cells

1. Introduction
Definitions
Group technology
Group technology is a philosophy in which similar parts are identified and grouped together to take advantage of their similarities in design and production.

Part family
Part 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.

Cellular manufacturing
Cellular manufacturing is grouping the production equipment into machine cells, where each cell specializes in the production of a particular part family.

1. Introduction
Features of group technology
Objective
To make batch production more efficient and productive. To integrate design and manufacturing in a firm. Obstacles Identifying the part families. Rearranging production machines into machine cells. Benefits It promotes standardization It reduces material handling, setup times and work-in-process Workers satisfaction and quality work improve

1. Introduction
The changeover from a conventional production to group technology
Three methods to group the parts into families: 1) Visual inspection 2) Parts classification and coding 3) Production flow analysis

1) Visual inspection It involves the classification of parts into families by looking at either the physical parts or their photographs and arranging them into groups having similar features.

2. Parts classification and coding

Definition
Each part family is exclusively identified by an alphanumerical code, which represents their design attributes, manufacturing attributes or both.

Features
Advantages Design retrieval Automated process planning Machine cell design

Methods to obtain the code from a particular part

Looking in tables to match the subject part against the features described. Using a computerized classification and coding system to reply questions about the parts features.

2. Parts classification and coding

Parts coding systems
Opitz Brisch System CODE CUTPLAN

DCLASS

MultiClass

Part Analog System

Types of structures of coding systems

Hierarchical / monocode Chain-type / polycode Mixed-mode
e.g. MultiClass (by Organization for Industrial Research) e.g. Opitz Classification System (by H. Opitz)

2. Parts classification and coding

Opitz Coding System
Digit sequence:

12345

6789

ABCD

Form code: design attributes

Supplementary code: manufacturing attributes

Secondary code: operation sequence and particular needs

2. Parts classification and coding

Opitz Coding System
Digit 1
Part Class

Digit 2
Main Shape

Digit 3
Rotational Machining

Digit 4
Plane Surface Machining

Digit 5
Additional Holes Teeth and Forming Other holes and teeth

Digits 6 7 8 9

0 1 2 3 4 5 6
Non-rotational Rotational

L/D 0,5 0,5 < L/D < 3 L/D 3 With deviation L/D 2 With deviation L/D > 2 Special A/B 3 A/C 4 A/B > 3 A/B 3 A/C < 4 Special External Shape Element Internal Shape Element Machining of plane surface

Original shape of raw materials Supplementary Material code

Main Shape

Rotational Machining

Form code
Main Shape Main Shape Main Shape Main bore and rotational machining

Machining of plane surface

Other holes, teeth and forming

Dimensions

Accurany

7 8 9

Machining of plane surface

Other holes, teeth and forming

2. Parts classification and coding

Opitz Coding System
Digit 1
Part Class

Digit 2
External shape, external shape elements

Digit 3
Internal shape, internal shape elements

Digit 4
Plane surface machining

Digit 5
Auxiliary holes and gear teeth

0 1 2 3 4 5 6
Rotational Non-rotational

L/D 0,5 0,5 < L/D < 3 L/D 3 With deviation L/D 2

0
Stepped to one end Stepped to both ends

Smooth, no shape elements No shape elements Thread Or smooth

0 1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

No hole, no breakthrough No shape elements Thread

0 1 2

No surface machining Surface plane and/or curved in one direction, external External plane surface related by graduation around the circle External groove and/or slot

0 1 2 3
No gear teeth

No auxiliary hole Axial, not on pitch circle diameter Axial on pitch circle diameter Radial, not on pitch circle diameter Axial and/or radial and/or other directions Axial and/or radial on PCD and/or other directions Spur gear teeth With gear teeth

Smooth or stepped to one end Stepped to both ends

Functional groove

Functional groove

3 4

No shape elements Thread

No shape elements
External spline External plane surface and/or slot, external spline

4 5 5 6 7

Thread

Functional groove

Functional groove

7 8 9

6
7

Internal plane surface and/or slot

Internal spline Internal and external polygon, groove and/or slot All others

Functional cone Operating thread All others

Functional cone Operating thread

Bevel gear teeth

8
All others

8
9

Other gear teeth

All others

2. Parts classification and coding

Opitz Coding System
Example Given this rotational part design, determine the form code in the Opitz parts classification and coding system.

13 UNC

1,0

0,3

0,7

0,5 0,8 1,5

 13 UNC

1,0

0,3

0,7

Form code

1
0,5 0,8 1,5

Digit 1
Part Class

Digit 2
External shape, external shape elements

Digit 3
Internal shape, internal shape elements

Digit 4
Plane surface machining

Digit 5
Auxiliary holes and gear teeth

0 1 2 3 4 5 6
Rotational Non-rotational

L/D 0,5 0,5 < L/D < 3 L/D 3

0
Stepped to one end Stepped to both ends

Smooth, no shape elements No shape elements Thread Or smooth

0 1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

No hole, no breakthrough No shape elements Thread

0 1 2

No surface machining Surface plane and/or curved in one direction, external External plane surface related by graduation around the circle

0 1 2 3
No gear teeth

No auxiliary hole Axial, not on pitch circle diameter Axial on pitch circle diameter Radial, not on pitch circle diameter

Smooth or stepped to one end Stepped to both ends

Functional groove

No shape elements Thread

3 External groove and/or slot Auxiliary External Plane Internal Length-to-diameter surface holes, shape: shape: gear machining: stepped part teeth, contains ratio on etc.: none both a none Axial and/or radial No shape elements and/or other 4 ends with screw through-hole thread on one end External spline directions 4 L/D = 1,5 Axial and/or radial
Thread

Functional groove

External plane surface and/or slot, external spline

5 6
With gear teeth

on PCD and/or other directions Spur gear teeth

Functional groove

Functional groove

7 8 9

6
7

Internal plane surface and/or slot

Internal spline Internal and external polygon, groove and/or slot All others

Functional cone Operating thread All others

Functional cone

Bevel gear teeth

Operating thread

8
All others

8
9

Other gear teeth

All others

2. Parts classification and coding

MultiClass Coding System
Coding structure: up to 30 digits divided into 2 regions

Region 1
Digit Function

0 1 2, 3 4 18

Code system prefix Main shape category External and internal configuration Machined secondary elements Etc. Machined element orientation

Region 2: designed by the user to meet specific needs and requirements.

2. Parts classification and coding

MultiClass Coding System
Example Given this rotational part design, determine the form code in the MultiClass parts coding system.

2. Parts classification and coding

MultiClass Coding System
Solution

3. Production Flow Analysis

Definition Production flow analysis (PFA) is a method for identifying part families and associated machine groupings that uses the information contained on production route sheets rather than on part drawings. Workparts with identical or similar routings are classified into part families. Then, the families can be used to form logical machine cells in a group technology layout. Possible anomalies

Parts whose basic geometries are quite different may nevertheless require similar or even identical process routings. Parts whose geometry are quite similar may nevertheless require process routings that are quite different.

Virtue Require less time than a complete parts classification and coding procedure.

3. Production Flow Analysis

Procedure

1. Scope of the analysis: The production flow analysis must begin defining the scope of the study (population of parts to be analyzed).
2. Data collection: The minimum data needed in the analysis are the part number and operation sequence. Additional data: lot size, time standards, and annual demand might be useful. 3. Sortation of process routings: Parts are arranged into groups according to the similarity of their process routings. To make this: a) All operations or machines are reduced to code numbers; b) For each part, operation codes are listed in the order they are performed c) A sortation procedure is then used to arrange parts into packs.

3. Production Flow Analysis

Procedure

4. PFA Chart: The processes used for each pack are then displayed in a PFA chart. PFA chart has been referred as part-machine incidence matrix.

xij = 1 Part i requires processing on machine j

xij = 0 Part i is not processed on machine j

3. Production Flow Analysis

Procedure 5. Cluster analysis: From the pattern of data in the PFA chart, related groupings are identified an rearranged into a new pattern that brings together packs with similar machine sequences. - Different machine groupings are indicated with blocks. - The blocks might be considered as possible machine cells.

Weakness The data used in the technique are derived form existing production route sheets. The routings may contain operations that are nonoptimal, illogical or unnecessary.

4. Cellular Manufacturing
Definition Cellular manufacturing is an application of group technology in which dissimilar machines or processes have been aggregated into cells, each of which is dedicated to the production of a part or product family or limited groups of families. Objectives To shorten manufacturing lead times. To reduce work in process inventory. To improve quality. To simplify production scheduling. To reduce setup times.

4. Cellular Manufacturing
4.1. Composite Part Concept
Definition Composite Part Concept is a hypothetical part for a given family which includes all of the design and manufacturing attributes of the family. An individual part in the family will have some features that characterize the family but not all of them. The composite part possesses all of them. Production cell design A production cell designed for the part family would include all the machines required to make the composite part. Such a cell would be capable of producing any member of the family, simply by omitting those operations corresponding to features not possessed by the particular part. The cell would also be designed to allow size variations within the family as well as feature variations.

4. Cellular Manufacturing

4. Cellular Manufacturing
4.2. Machine cell design
Types of Machine Cells and Layouts
Manufacturing cells can be classified according to the number of machines and the degree to which the material flow is mechanized between machines. Four common GT cell configurations: 1. Single machine cell: Consists on one machine plus supporting fixtures and tooling. This type of cell can be applied to workparts whose attributes allow them to be made on one basic type of process such as turning or milling.

4. Cellular Manufacturing
2. Group machine cell with manual handling: an arrangement of more than one machine used collectively to produce one or more part families. - There is no provision for mechanized parts movement between the machines in the cell. Instead, the human operators who run the cell perform the material handling function. - The cell is often organized into a U-shaped layout. This layout is appropriate when there is variation in the work flow and to allow the multifunctional workers in the cell to move easily between machines.

4. Cellular Manufacturing
3. Group machine cell with semi-integrated handling: uses a mechanized handling system to move parts between machines in the cell. 4. Flexible manufacturing system (FMS): combines a fully integrated material handling system with automated processing stations. - FMS is the most highly automated of the group technology machines cell. - Variety of layouts: U-shape, in-line, loop, and rectangular.

4. Cellular Manufacturing
Cell design
Part movement Four types of part movement:

1. Repeat operation: a consecutive operation is carried out on the same machine so the part does not actually move. 2. In-sequence move: the part moves from the current machine to an immediate neighbor in the forward direction.
3. By-passing move: the part moves forward from the current machine to another machine that is two or more machines ahead. 4. Backtracking move: the part moves from the current machine in the backward direction to another machine.

4. Cellular Manufacturing
Movement Repeat operations In-sequence move Passing moves Backtracking move Layout Multiple stations (machines) In-line layout / U-shaped layout U-shaped layout Loop or rectangular layout

Additional factors Additional factors that must be accounted for in the cell design: Quantity of work to be done by the cell: number of parts per year and processing time per part at each station. Determine the workload and therefore the number of machines that must be included.

Part size, shape, weight, and other physical attributes: determine the size and type of material handling and processing equipment that must be used.

4. Cellular Manufacturing
Key machine concept Key machine is a certain machine in a cell that is more expensive to operate than the other machines or that performs certain critical operations in the plant. The other machines are referred to as supporting machines, and they should be organized in the cell to keep the key machine busy. In a sense, the cell is designed so that the key machine becomes the bottleneck of the system.

The key machine concept is sometimes used to plan the GT machine cell. The approach is to decide what parts should be processed through the key machine and then determine what supporting machines are required.

4. Cellular Manufacturing
Utilization measures Two measures of utilization: 1. Utilization of the key machine: using the usual definition. The utilization of each of the other machines can also be evaluated similarly. 2. Utilization of the overall cell: obtained by taking a simple arithmetic average of all the machines in the cell.

5. Application considerations in group technology

5.1. Applications of Group Technology
5.1.1. Manufacturing Applications Informal scheduling and routing of similar parts through selected machines

1. Formation of cells
Virtual machine cells Formal machine cells

2. Process planning of new parts

3. Family tooling 4. Parametric programming

5. Application considerations in group technology

5.1. Application of Group Technology
5.1.2. Product Design Applications 1. Use of design retrieval systems Design savings

Simplify design procedures Reduce part proliferation 2. Simplification and standardization of design parameters Reduce the required number of tools Reduce the amount of data and information that the company must deal with

5. Application considerations in group technology

5.2. Survey of Industry Practice
Rank Reason for installing Manufacturing Cells

1 2 3 4 5 6 7 8 9 10 11

Reduce throughput time (Manuf. Lead time) Reduce work-in-process Improve part and/or product quality Reduce response time for customer orders Reduce move distances Increase manufacturing flexibility Reduce unit costs Simplify production planning and control Facilitate employee involvement Reduce setup times Reduce finished goods inventory

5. Application considerations in group technology

5.2. Survey of Industry Practice

Rank

Costs of Introducing Cellular Manufacturing

1 2 3 4 5 6 7 8 9

Relocation and installation of machines Feasibility studies, planning and design New equipment and duplication of equipment Training New tooling and fixtures Programmable controllers, computers and software Material handling equipment Lost production time during installation Higher operator wages

6. Quantitative analysis in cellular manufacturing

Quantitative techniques have been developed to deal with problem areas in GT
Grouping parts and machines into families

Two main problem areas

Rank order clustering Arranging machines in a GT cell

An heuristic approach by Hollier

6. Quantitative analysis in cellular manufacturing

6.1. Rank Order Clustering Technique Specially applicable in production flow analysis It works by reducing the part-machine incidence matrix to a set of diagonalized blocks that represent part families and machine cells.
Algorithm

1. Read each row of the matrix as a binary number and reorder them in decreasing order. 2. Do the same with the columns of the matrix 3. Repeat steps 1 and 2 until no change in the matrix is needed.

6. Quantitative analysis in cellular manufacturing

6.1. Rank Order Clustering Technique
6.1.2. Example

Parts

Parts

Machines
1 2 3

A
1

D
1

F
1

Machines
1 4 3

A
1 1

F
1 1

D
1

1 1 1

1 1

6. Quantitative analysis in cellular manufacturing

6.1. Rank Order Clustering Technique
6.1.2. Example

Parts Machines
1

Parts

A
1

F
1

D
1

B
1

Machines
1a 4

A
1 1

F
1 1

4 3
2

1 1
1

1
1 1

1b 2

1 1

1 1 1

6. Quantitative analysis in cellular manufacturing

6.2. Hollier Method to Arrange Machines in a GT Cell Uses data contained in From-To charts Maximizes the proportion of in-sequence moves within the cell

Algorithm

1. Develop the From-To chart

2. Determine the From/To ratio for each machine 3. Arrange machines in order of decreasing From/To ratio

6. Quantitative analysis in cellular manufacturing

6.2. Hollier Method to Arrange Machines in a GT Cell
6.2.2. Example

50 parts processed on 4 machines.

To: From: 1 2 3 4 1 0 30 10 10 2 5 0 40 0 3 0 0 0 0 4 25 15 0 0 From Sums 30 45 50 10 From/To Ratio 0.60 1.0 0.25

To Sums

50

45

40

6. Quantitative analysis in cellular manufacturing

6.2. Hollier Method to Arrange Machines in a GT Cell
6.2.2. Example

Flow diagram
10
50 in 3 40 2 30 5 Percentages of in-sequence moves = 70.4% Percentages of backtracking moves = 11.1% 1

15
25 4 10 20 out 30 out

Questions