GROUP TECHNOLOGY

Group technology is a manufacturing philosophy in which similar parts are identified and grouped together to take advantage of their similarities in manufacturing and design.
Similar parts are arranged into part families. Part similarities are of two types: Design attributes ( such as geometric shape and size), and Manufacturing attributes (sequence of processing steps required to make the part)

PART FAMILIES
A part family is a collection of parts which are similar either because of geometric shape and size or because of similar processing steps are required in their manufacture.

Process Layout
In process type layout various machine tools are arranged by function. There is lathe, drilling, milling machine and so on. During the machining of the part the work piece must be moved between sections, with perhaps same section being visited several times. This results in significant amount of material handling, large process inventory, more setups than necessary, long manufacturing lead times and high cost

Group Technology Layout

Here the machines are arranged into cells. Each cell is organised to specialize in manufacture of a particular part family. Advantages gained are reduced material handling, lower setup times, lower in-process inventory, shorter lead times. Manufacturing cells can be designed to form production flow lines with conveyors used to transport work parts between machine cells

The biggest single obstacle in changing over to group technology from a production shop is the problem of grouping parts into families. There are three methods for solving this problem. All three methods are time consuming and involves the analysis of much data by properly trained personnel. The three methods are: 1. Visual inspection 2.Classification and coding by examination of design and production 3. Production flow analysis (PFA)

Visual Inspection
The visual inspection method is the least sophisticated and least expensive method. It involves the classification of parts into families by looking at either the physical parts or their photographs and arranging them into similar groupings. This method generally considered to be the least accurate of the three methods.

Classification and coding by examination of design and production

It 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. It 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.

Production flow analysis (PFA)

It makes use of the information contained on route sheets rather than part drawings. Work parts with identical or similar routings are classified into part families.

PARTS CLASSIFICATION AND CODING

The major benefits of a well-designed classification and coding system . 1. It facilitates the formation of part families and machine cells. 2. It permits quick retrieval of designs, drawings, and process plans. 3. It reduces design duplication. 4. It provides reliable workpiece statistics. 5. It facilitates accurate estimation of machine tool requirements. 6. It reduces setup time and reduces production output time. 7. It aids production planning and scheduling procedures. 8. It improves cost estimation. 9. It provides for better machine tool utilization and better use of tools, fixtures, and manpower.

Types of classification and coding systems

Parts classification systems fall into one of three categories: 1. Systems based on part design attributes. 2. Systems based on part manufacturing attributes. 3. Systems based on both design and manufacturing attributes.

 The parts coding scheme consists of a sequence of numerical digits devised to identify the part's design and manufacturing attributes. Coding schemes for parts classification can be of two basic structures: -

1. Hierarchical structure. In this code structure, the interpretation of each succeeding symbol depends on the value of the preceding symbols.

2. Chain-type structure. In this type of code, the interpretation of each symbol in the sequence is fixed. It does not depend on the value of the preceding symbol.

 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.

Two classification and coding systems will be discussed , they are: The Opitz system and Multi Class(MICLASS)

The Optiz Classification System

The Optiz coding system uses the following digit sequence: 12345 6789 ABCD
The basic code consists of nine digits, which can be extended by adding four more digits. The first nine digits are intended to convey both design and manufacturing data. The first five digits, 12345 are called the form code and describes the primary design attributes of the part. Then next four digits, 6789, constitute the "supplementary code" which indicates the manufacturing attributes (dimensions, work material, starting raw workpiece shape and accuracy). Extra four digits, ABCD, are referred to as the "secondary code" and are intended to identify the production operation type and sequence. The secondary code can be designed by the firm to serve its own particular
needs.

 The overall length/diameter. ratio, LID = 1.5, so the first digit code = 1.
The part is stepped at both ends with a screw thread on one end, so the second-digit code would be 5. The third digit code is 1 because of the through-hole. The fourth and fifth digits are both 0, since no surface machining is required and there are no auxiliary holes or gear teeth on the part. The complete form code in the Opitz system is 15100. To add the supplementary code, we would have to code the sixth through ninth digits with data on dimensions, material, starting workpiece and shape and accuracy.