MM 323 MANUFACTURING SYSTEMS

Group Technology and Cellular Manufacturing

WHAT ARE WE GOING TO LEARN?

1. 2. 3. 4. 5. Part Families Parts Classification and Coding Production Flow Analysis Cellular Manufacturing Quantitative Analysis in Cellular Manufacturing

GROUP TECHNOLOGY AND CELLULAR MANUFACTURING

GROUP TECHNOLOGY (GT) forms the part families Reviewing all of the parts made in the plant and grouping them into part families based on their SIMILARITIES Similar parts are identified and grouped together to take advantage of their similarities in design and production CELLULAR MANUFACTURING (CM) rearranges production machines into Group Technology (MACHINE) cells Physically rearranges the machines into cells. Each part family (parts in each part family have similar processes/processing steps/ holding systems (jigs, fixtures, )) is manufactured in a seperate machine cell.

WHAT DOES GROUP TECHNOLOGY AND CELLULAR MANUFACTURING BRING?

GT: Drawing, process planning and production scheduling are simplified GT and CM: Standardization of drawings, process plans, tooling, fixtures, and setups is encouraged CM: Material handling is reduced Parts are moved within a machine cell rather than the entire factory CM: Work-in-process and manufacturing lead time are reduced CM: Improved worker satisfaction in a GT cell GT and CM: Higher quality work

GROUP TECHNOLOGY:Part Family

A collection of parts that possess similarities in geometric shape and size, or in the processing steps used in their manufacture Part families are a central feature of group technology There are always differences among parts in a family But the similarities are close enough that the parts can be grouped into the same family Group Technology can be applied ALONE in DESIGN AND PRODUCTION PLANNING DEPARTMENTS to reduce drawings and process plan (processes, machines, tooling and fastener requirements) preparation times by modifying the existing or using the same part designs. Design retrieval systems are incorporated into CAD/CAM systems.

Part Family: How do you define SIMILARITY?

Two parts that are identical in shape and size but quite different in manufacturing --WHY? --BECAUSE (a) 1,000,000 units/yr, tolerance = 0.010 inch, 1015 CR steel, nickel plate (b) 100/yr, tolerance = 0.001 inch, 18-8 stainless steel

Ten parts that are different in size and shape, but quite similar in terms of manufacturing. --WHY? --BECAUSE all ten parts are machined from cylindrical stock by turning; some parts require drilling and/or milling

Ways to Identify Part Families

1. Visual inspection Using best judgment and YOUR EYES to group parts into appropriate families, based on the parts or photos of the parts

2. Parts classification and coding

Identifying similarities and differences among parts and relating them by means of a coding scheme 3. Production flow analysis Using information contained on route sheets to classify parts. Workparts with identical or similar routings are classified into part families. Forms the part families and machine cells simultaneously. Generally used to form machine cells in cellular manufacturing.

2. PART CLASSIFICATION AND CODING

Identification of similarities among parts and relating the similarities by means of a numerical coding system Involves classifying the parts into families by examining the individual design and/or manufacturing attributes of each part. The classification results in a code number that uniquely identifies the part's attributes. This classification and coding may be carried out on the entire list of active parts of the firm or some sort of sampling procedure may be used to establish the part families. Most time consuming of the three methods Must be customized for a given company or industry Reasons for using a coding scheme: Design retrieval Automated process planning

2. PARTS CLASSIFICATION AND CODING

Although there are several commercially available packages being sold to industrial concerns A CRITICAL QUESTION:
HOW DOES ONE USE PART CLASSIFICATION AND CODING SCHEMES TO FORM PART FAMILIES AND MACHINE CELLS? THERE IS NOT A WELL DEFINED ANSWER. MAYBE COMPOSITE PART CONCEPT CAN BE USED.

Parts Classification and Coding Systems

Most classification and coding systems are one of the following: Systems based on part design attributes Systems based on part manufacturing attributes Systems based on both design and manufacturing attributes
Part Design Attributes
Major dimensions Minor dimensions Basic external shape Tolerances Basic internal shape Part function Length/diameter ratio Material type Surface finish

Part Manufacturing Attributes

Major process Operation sequence Batch size Annual production Machine tools Material type Minor operations Production time Major dimension Length/diameter ratio Cutting tools

Surface finish

Fixtures needed

Coding Scheme Structures

1. Hierarchical structure (monocode) Interpretation of each successive digit depends on the value of the preceding digit 2. Chain-type structure (polycode) Interpretation of each symbol is always the same No dependence on previous digits
EXAMPLE: Consider a two-digit code, such as 15 or 25. Suppose that the first digit stands for the general part shape. The symbol 1 means round workpart and 2 means flat rectangular geometry. In a hierarchical code structure, the interpretation of the second digit would depend on the value of the first digit. If preceded by 1, the 5 might indicate some length/diameter ratio, and if preceded by 2, the 5 might be interpreted to specify some overall length. In the chain-type code structure, the symbol 5 would be interpreted the same way regardless of the value of the first digit. For example, it might indicate overall part length, whether the part is rotational or flat rectangular. The advantage of the hierarchical code structure is that more information can be contained in the code.

3. Mixed-code structure Combination of hierarchical and chain-type structures

Coding Scheme Structures

The number of digits required can range from 6 to 30. Coding schemes that include only design characteristics require fewer digits, perhaps 12 or fewer. Most modern classification and coding systems incorporate both design and manufacturing data into the code. To accomplish this, code numbers with 20 to 30 digits may be needed.

Some of the important classification and coding systems include the Opitz (University of Aachen), Brisch System (Brisch-Bim, Inc.), CODE (Manufacturing Data Systems, Inc.), CUTPLAN (Metcut Associates), DCLASS (Brigham Young University), MultiClass (OIR-Organization for Industrial Research), and Part Analog System (Lovelace, Lawrence & Co., Inc.).

Parts Classification and Coding Systems

OPITZ classification system
12345 6789 ABCD 12345 (Form code) describes primary design attribute 6789 (Supplementary code) describes the attributes that should be used in manufacturing ABCD (Secondary code) identifies the production operation type and sequence

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Opitz Classification System

One of the first published classification and coding schemes for mechanical parts Basic code = nine (9) digits Digits 1 through 5 = form code primary shape and design attributes (hierarchical structure) Digits 6 through 9 = supplementary code attributes that are useful in manufacturing (e.g., dimensions, starting material) Digits 10 through 13 = secondary code production operation type and sequence

Basic Structure of Opitz System

Opitz Form Code (Digits 1 through 5)

Example: Opitz Form Code

Form code in Opitz system is 15100

Parts Classification and Coding Systems

MULTICLASS classification system
* Hierarchical or decision-tree coding structure
* Up to 30 digit code

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What does a Well-Designed Classification and Coding System bring?

Facilitates formation of part families--- HOW? Permits quick retrieval of part design drawings Reduces design duplication Promotes design standardization Improves cost estimating and cost accounting Facilitates NC part programming by allowing new parts to use the same part program as existing parts in the same family Computer-aided process planning (CAPP) becomes feasible

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CELLULAR MANUFACTURING
Parts in the medium production quantity range are usually made in batches using a function type layout Disadvantages of batch production: Long downtime for changeovers High inprocess inventories (WIP) and inventory carrying costs Long manufacturing lead times

CELLULAR MANUFACTURING forms machine cells. Each machine cell is designed to produce a given part family, or a limited collection of part families.

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BEFORE: Traditional Function Layout

Follow a BATCH and try to visualize WHAT HAPPENS during set-up; process; move; wait activities. Hint: A part waits completion of its batch before moving to its next activity. How much time does a part wait in each activity?

AFTER: Cellular Layout

Each cell specializes in producing one or a limited number of part families.

WHAT CHANGED ? ---Follow a part and

measure time for each activity (set-up time; move time ; process time; wait time) and compare them with the activity times of a part which belongs to a BATCH this time in function layout.

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Cellular Manufacturing
Dissimilar machines or processes are aggregated into cells, each of which is dedicated to the production of a part family or limited group of families. Each machine cell acts like a flow line. The set-up times are much lower because of the manufacturing similarities among parts in a part family. When set-up times are lower, batch sizes can be reduced to ONE. So, LOWER MANUFACTURING LEAD TIMES REDUCED WIP IMPROVED QUALITY

WHAT IS A MACHINE CELL?

THE MACHINES THAT ARE NEEDED TO MANUFACTURE A PART FAMILY COMPLETELY FORM A MACHINE CELL. THEN A MACHINE CELL CAN BE Single machine Multiple machines with manual handling Often organized into U-shaped layout Multiple machines with semi-integrated handling Automated cell automated processing and integrated handling Flexible manufacturing cell Flexible manufacturing system

1. 2. 3. 4.

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2. A Machine Cell with Multiple machines with Manual Handling

U-shaped machine cell with multiple machines and

manual part handling between machines

Examples for A Machine Cell with Multiple machines with Manual Handling

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3. A Machine Cell with Multiple machines with semi-integrated handling

In-line layout using mechanized work handling (CONVEYOR) between machines. But workers load and unload machines.

3. A Machine Cell with Multiple machines with semi-integrated handling

SAME mechanized work handling (CONVEYOR) between machines and manual loading and unloading of parts at machines. But LOOP layout allows variations in part routing between machines

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3. A Machine Cell with Multiple machines with semi-integrated handling

RECTANGULAR layout also allows variations in part routing and allows for return of work carriers when they are used.

4. Automated machine cell automated processing and integrated handling (FULLY INTEGRATED): Flexible manufacturing system

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Up to now we were dealing with A SINGLE MACHINE CELL LAYOUT. A CRITICAL QUESTION: HOW CAN WE PUT THEM TOGETHER IN PLANT LAYOUT? AN EXAMPLE FOR PLANT LAYOUT: Group machine cells with U-shaped

layout combined together in a manufacturing hall

HOW TO SELECT MACHINES TO PRODUCE A PART FAMILY?

1) COMPOSITE PART CONCEPT 2) PRODUCTION FLOW ANALYSIS

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1. COMPOSITE PART Concept

A composite part for a given family is a hypothetical part that includes all of the design and manufacturing attributes of the family In general, an individual part in the family will have some of the features of the family, but not all of them A machine cell for the part family would consist of those machines required to make the composite part Such a cell would be able to produce any family member, by omitting operations corresponding to features not possessed by that part

1. Composite Part Concept

Composite part concept: (a) the composite part for a family of machined rotational parts, and (b) the individual features of the composite part

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1. Composite Part Concept Part Features and Corresponding Manufacturing Operations Design feature 1. External cylinder 2. Face of cylinder 3. Cylindrical step 4. Smooth surface 5. Axial hole 6. Counter bore 7. Internal threads AGAIN

Corresponding operation Turning Facing Turning External cylindrical grinding Drilling Counterboring Tapping

A machine cell for the part family would consist of those machines required to make the composite part Such a cell would be able to produce any family member, by omitting operations corresponding to features not possessed by that part

2. PRODUCTION FLOW ANALYSIS (PFA)

Part families and machine cells are formed simultaneously. Identifies part families and associated machine cells based on PRODUCTION ROUTE SHEETS rather than part design data Workparts with identical or similar route sheets are classified into part families.

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2. Production Flow Analysis

ROC (Rank Order Clustering) (sral kmeleme algoritmas) Algorithm to Form Machine Groups

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ROC (Rank Order Clustering) (sral kmeleme algoritmas) Algorithm to Form Machine Groups

ROC (Rank Order Clustering) (sral kmeleme algoritmas) Algorithm to Form Machine Groups

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How To Determine the Sequence of Machines, their layout and automation level in a Machine Cell ?
Once the machine cells are determined two questions arise 1) The sequence of machines in the cell 2) The layout type (U, in-line, loop, rectangular) and mechanization/automation level ( human; semiintegrated; fully integrated)

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The sequence of machines can be determined by Hollier Method 1 and Hollier Method 2.
Hollier Method 1

INEG 4523 Automated Production Dr. Buyurgan

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 Hollier Method 2

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Is the determined sequence of machines in the cell OKEY?

----Backtracking moves distrupt the natural flow of parts. There must be a very low backtracking move percentage.

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EXAMPLE (for sequence of machines)

EXAMPLE (for sequence of machines)

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EXAMPLE (for sequence of machines)

ONCE THE CELLS ARE FORMED THEN WHAT?

HOW DO WE ORDER (START TIME AND PRODUCTION SIZE) PRODUCTION AT WORK STATIONS? --------PUSH VS PULL PRODUCTION ORDER SYSTEMS

Push

External Control

Pull

Kanban Squares - Control Comes From Within the System

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KANBAN SQUARES---- HOW DO THEY OPERATE? Inventory Places

1) CUSTOMERS REMOVE FROM FINISHED GOODS INVENTORY. 2) MACHINE 3 REMOVES NECESSARY PART(S) FROM ITS INPUT INVENTORY AND STARTS TO PRODUCE A NEW PART TO FILL FINISHED GOODS INVENTORY. 3) MACHINE 2 REMOVES NECESSARY PART(S) FROM ITS INPUT INVENTORY AND STARTS TO PRODUCE A NEW PART TO FILL FINISHED GOODS INVENTORY. 4) MACHINE 1 REMOVES NECESSARY PART(S) FROM THE RAW MATERIAL INVENTORY AND STARTS TO PRODUCE A NEW PART TO FILL FINISHED GOODS INVENTORY. 5) NEW RAW MATERIALS ARE DEPOSITED TO FILL THE EMPTY PLACES AT RAW MATERIAL INVENTORY.

Machine 1

Machine 2

Machine 3

Raw Material

Finished Goods

Production Triggered

Production Triggered

Production Product Triggered Consumed

Two Card Kanban PULL SYSTEM (PRODUCTION AND WITHDRAWAL KANBANS) Step 1
Empty Container from Downstream Workcentre
P W

Input Queue
W W

Machine

Output Queue
P

Step 1

Withdrawal Kanban

Production Kanban

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Two Card Kanban Steps 2 and 3

W W

Step 2

P W

Full Container Sent to Downstream Workcentre

P

Production Kanban Removed From Empty Container --PRODUCTION KANBAN GIVES AN PRODUCTION ORDER TO THE MACHINE.

Step 3

Production Kanban removes input raw material and PRODUCES to fill the empty place. Now input container is EMPTY.

Two Card Kanban Steps 4 and 5

W W W P P W

Step 4

Empty Container Sent to Upstream Workcentre

W W W

Step 5

Full Container From Upstream Workcentre

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