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GROUP TECHNOLOGY
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TRANSFER
LINE
SPECIAL
VOLUME
SYSTEM
FLEXIBLE
MANUFACTURING
SYSTEM
MANUFACTURING
Cells
LOW HIGH
VARIETY
EVERYDAY EXAMPLES
A FAMILY OF PARTS
PRODUCTION
FAMILY
LACK OF COMMON DATABASE FOR
MFG., DESIGN...
DONT REDESIGN THE WHEEL
AUTOMATED PROCESS PLANNING
DATABASE TO DRIVE THE
AUTOMATED FACTORY
BENEFITS OF GROUP TECHNOLOGY
REDUCTIONS IN
THROUGHPUT TIME
SET-UP TIME
OVERDUE ORDERS
CAPITAL EXPENDITURES
TOOLING COSTS
ENGINEERING TIME AND COSTS
MAINTENANCE INVENTORY
TOOL PLANNING
ENGINEERING
ESTIMATING PURCHASING
INDUSTRIAL ASSEMBLY
RELATIONS
QUALITY MANAGEMENT
CONTROL
R&D MFG.
ENGINEERING
COST GT SHIPPING &
ACCOUNTING RECEIVING
THREE TECHNIQUES TO FORM PART FAMILIES
1. TACIT JUDGMENT OR VISUAL
INSPECTION
MAY USE PHOTOS OR PART
PRINTS
UTILIZES SUBJECTIVE
JUDGMENT
LENGTH/DIAMETER RATIO
SURFACE FINISH
TOLERANCES-----MACHINE TOOL
OPERATION SEQUENCE
MAJOR DIMENSION
TOOLING
BATCH SIZE
GT CODE--A SEQUENCE OF NUMERICAL DIGITS
DIFFICULT TO CONSTRUCT
PROVIDES A DEEP ANALYSIS
USUALLY FOR PERMANENT INFORMATION
contd
2. POLYCODE (OR CHAIN-TYPE STRUCTURE)
EACH DIGIT IS INDEPENDENT OF ALL OTHERS,
PRESENTS INFORMATION NOT DEPENDENT
ON PREVIOUS ONES
EASIER TO ACCOMMODATE
CHANGE
3. MIXED CODE
HAS SOME DIGITS FORMING MONOCODES, BUT
STRINGS THEM TOGETHER IN THE GENERAL
ARRANGEMENT OF A POLYCODE
MAPPING FROM POPULATION
SPACE TO CODE SPACE
POPULATION
SPACE
H
P
CODE
SPACE
C
HIERARCHICAL STRUCTURE
32XX
321X 323X
Mechanical
Transmission
3231 3233
322X
UNF thread 3232
3221 3223
322
2
HYBRID STRUCTURE
0 6 12 18 24 36
Time (months)
PROLIFERATION OF PARTS
SELECTION OF OPTICAL INSTRUMENT PARTS IN ONE COMPANY,
ILLUSTRATING THE SIMILARITY BETWEEN CERTAIN COMPONENTS
Design
archive
Retrieval existing designs
Existing designs
New Design
TECHNIQUE:
D D
L L M M
Grinding
L L M M G G
Assembly
L L G G
A A
Receiving and A A G G
Shipping
PROCESS-TYPE LAYOUT
GROUP TECHNOLOGY LAYOUT
L L M D G
A A
Receiving L M G G
L M D Shipping
CELLULAR LAYOUT
Department #2 Department #1
D D M I D
I
L
Department #3
M
M
L L D M I
1st Digit
FORM CODE
5th Digit Supplim-
part class 3rd Digit 4th Digit entary
2nd Digit additional
main shape rotational plane surface holes teeth & code
Positions
with a 0 machining matching forming
Digit
digit External Internal Machining 6 7 8 9
1 shape shape of plane Other holes
element element surfaces and teeth
2
Machining Other holes
3 Main shape Rotational teeth and
of plane
machining
Dimensions
surfaces forming
Accuracy
Material
4
6
Non-rotational
Process
APT Processor
& post-processor
PROCESS PLANNING
Bridge
Design Manufacturing
VARIANT PROCESS PLANNING
USES THE SIMILARITY AMONG COMPONENTS
TO RETRIEVE EXISTING PROCESS PLANS
(WHICH CAN BE MODIFIED)
OVERVIEW:
TWO STAGES FOR VP SYSTEMS
1. PREPARATORY STAGE
EXISTING PARTS CODED &
CLASSIFIED (I.E. GT IS A
PREREQUISITE)
PART FAMILIES ORGANIZED
STANDARD PLANS DEVELOPED
DATABASES CREATED
(NOTE: THIS STAGE IS LABOR INTENSIVE)
Contd
1. PREPARATORY STAGE OF
VARIANT
PROCESS PLANNING
Part Drawing
Coding
Family One
Standard
Plan
File
Family Formation
(Indexed
by Family
Matrix)
Process Plan
2. PRODUCTON STAGE OF VARIANT
PROCESS PLANNING
Process Plan
Editing Standard
Plan
Retrieval