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Topics on Quality, Lean

Manufacturing and Productivity


Improvement

CELLULAR
MANUFACTURING
(FLEXIBLE OPERATIONS)
Presented by

JORGE ROS

Cellular Manufacturing

Cellular Manufacturing is an approach


in which equipment and workstations
necessary to produce a product are
arranged closely together to facilitate
small lot continuous flow production.
The goal is to have the necessary
flexibility to produce a variety of low
demand products, while maintaining
the same productivity obtained with a
large scale production.

Picture from Wikipedia

Traditional Batch Processing

One Piece Flow


Handling items one at a time eliminates wastes inherent in batch production
and enables a balanced flow of work.

Multi-Process Handling

Multi-functional Workforce

Zero Op-to-Op Transfer Times


All the operations necessary to produce a component or subassembly
are performed in close proximity. Near zero operation-to-operation
transfer times are achieved.

Cellular Manufacturing

Cell designers achieve this through modularity


in both process design and product design.
The biggest challenge when implementing
cellular manufacturing in a company is dividing
the entire manufacturing system into cells.
The issues may be conceptually divided in the
"hard" issues of equipment, such as material
flow and layout, and the "soft" issues of
management, such as upskilling and corporate
culture.

Flow in a U-Cell
Equipment and Workstations used to produce are arranged to facilitate a
continuous production flow in small lots.
OUTPUT
Finished
Goods

Station 5

Station 1

Station 2

Station 3

Work
Flow

EXAMPLE
INPUT
(Components
and
Materials)

Station 4

Example Single Cell

Several Operators in Series


In a process with several operators, work is divided in small operations, so
that a group of operators team together to work at the same speed,
dividing the work load among them.

Cellular Lay Out

Combined Cellular Manufacturing

Pitfalls to avoid

Integrating Subassembly into Main Assembly

Implementing Flexible Operations