Cellular Manufacturing

and Facilities Layout

Dr. Richard A. Wysk rwysk@psu.edu http://www.engr.psu.edu/cim

Outline of Activities
Fundamentals of layout Advantages of various layouts Creating part families Economics of Cellular layout
scheduling setup reduction

Other issues

Readings
Chapter 18 of Computer Aided Manufacturing, Wang, H.P., Chang, T.C. and Wysk, R. A., 3rd Edition (2004 expected) http://www.engr.psu.edu/cim/active/chapter18.pdf

Exercise
Readiness Assessment Test
A.K.A. RAT

AS AN INDIVIDUAL, Describe what you think a part family is. Describe what you think a process family is. Which is the best way to cluster products in a manufacturing facility: a) the way a part looks, b) the function of the part, 3) the way the part is made. Why?
Open Book / Open Notes

Exercise
Readiness Assessment Test
AS A TEAM, take 5 minutes

A.K.A. RAT

Compare and discuss the efficiencies and the uses of the various ways to group stuff in a shop. Try to chalk out a best practice. List the criterion you used.

Open Book / Open Notes

Objectives
To apply the principles of flow to a complex manufacturing system To design the layout of process, product and cellular manufacturing systems To form cells in a manufacturing environment To analyze efficiencies of reduced batch sizes

Types of Manufacturing Layout

Process Layout Product Layout Cellular Layout

FUNCTIONAL LAYOUTS ARE INEFFICIENT

Lathe Milling Drilling

L L L L

L L L L

M M M A A

M M M
Assembly

D D
Grinding

D D

G G G

G G G

A A

Receiving and Shipping

PROCESS-TYPE LAYOUT

Process Layout Characteristics

Advantages
Deep knowledge of the process Common tooling and fixtures Most Flexible -- can produce many different part types

Disadvantages
Spaghetti flow -- everything gets all tangled up Lots of in-process materials Hard to control inter-department activities Can be difficult to automate

PRODUCT LAYOUT
Part #1 L L M D G A Receiving L Part #2 Part #3 M G G A

Shipping

Product Layout Characteristics

Advantages
Easy to control -- input control Minimum material handling -- frequently linked to the next process Minimal in-process materials Can be more easily automated

Disadvantages
Inflexible -- can only produce one or two parts Large setup Duplicate tooling is required for all cells

CELLULAR LAYOUT
Cell #2 D D Cell #3 M I Cell #1 D I L M M I M

Cellular Layout Characteristics

Advantages
Control is simplified Common tooling and fixtures Flexible -- can produce many different part types - a part family??

Disadvantages
Setup ?? Need to know about many different processes

HIGH

TRANSFER LINE
SPECIAL SYSTEM FLEXIBLE MANUFACTURING SYSTEM MANUFACTURING Cells STD. AND GEN. MACHINERY LOW HIGH

VOLUME

VARIETY

How are Cells Formed

Good intuition Careful study Group Technology (GT) Production Flow Analysis (PFA)

Typical Part Families

Items that are made with the same equipment Items that look alike

A FAMILY OF PARTS

PRODUCTION FAMILY

Items that are made with the same equipment - Production Flow Analysis
PFA is a technique that uses Operation Routing Summaries as input. It clusters the parts that require the same processes. These parts can then be assembled into a part family. The processes can be grouped into a cell to minimize material handling requirements.

Items that look alike

Most products that look similar are manufactured using similar production techniques. If parts are grouped because they have similar geometry (about the same size and shape), then they should represent a part family.

Grouping based on geometry or function

THREE TECHNIQUES TO FORM PART FAMILIES

1. TACIT JUDGMENT OR VISUAL INSPECTION MAY USE PHOTOS OR PART PRINTS UTILIZES SUBJECTIVE JUDGMENT 2. CLASSIFICATION & CODING BY EXAMINTAION OF DESIGN & PRODUCTION DATA MOST COMMON IN INDUSTRY MOST TIME CONSUMING & COMPLICATED
Contd

THREE TECHNIQUES TO FORM PART FAMILIES

3. PRODUCTION FLOW ANALYSIS USES INFORMATION CONTAINED ON THE ROUTE SHEET (THEREFORE ONLY MFG. INFO) PARTS GROUPED BY REQUIRED PROCESSING

Classification & Coding by Examination of Design & Production Data

Many systems have been developed but none is universally applicable and most implementations require some customization

Identifying Manufacturing Cells Using Production Flow Analysis

Production Flow Analysis

A technique for forming part families based on Operation Routing Summaries
Several methods available. We will discuss 2 algorithms for PFF (Part Family Formation)

Lets consider 5 parts (n) and 6 machines (m):

n = {101, 102, 103, 104, 105} m = {Drill1, Drill2, Mill1, Mill2, Vbore1, Vbore2} = {D1, D2, M1, M2, V1, V2}

Operation Routing Summary

Part No. 101 102 103 104 105 Routing D1 -M1 - V1 D2 -M2- V1 D1 -M1 M2 - V2 - D2 V1 - M1 - D1 Times (min) 9 - 12 - 14 5 - 11 - 14 7-9 8 - 12 - 5 7 - 10 - 12 Ave. Dem. 100 250 700 100 200

Create a PFA matrix, M

Parts
Drill1 Drill2 Mill1 Mill2 VB1 VB2 101 1 0 1 0 1 0 102 0 1 0 1 1 0 103 1 0 1 0 0 0 104 0 1 0 1 0 1 105 1 0 1 0 1 0

M =

Machines

Kings Algorithm (Rank Order Clustering)

Step#1 Calculate the total column width for each column

Generate 2i
wj =
Machine# 1 2 3 4 5 6

2 mi
i "i

(i)

Part# (j)

101 1 0 1 0 1 0 42

102 0 1 0 1 1 0 52

103 1 0 1 0 0 0 10

104 0 1 0 1 0 1 84

105 1 0 1 0 1 0 42

D1 D2 M1 M2 V1 V2

2 4 8 16 32 64

Sum: mi,j * 2i for each column (wj)

(wj)

#2.

If Wj is in ascending order, go to step #3; otherwise, rearrange the columns to make Wj fall in an ascending order.
101 103 D1 D2 M1 M2 V1 V2 1 0 1 0 0 0 10 101 1 0 1 0 1 0 42 105

105 1 0 1 0 1 0 42

102 0 1 0 1 1 0 52

104 0 1 0 1 1 0 84

i
14 48 14 48 28 32

wj

102
103 104

#3. "i, calculate the total row weight, wi

wi =
103 D1 D2 M1 M2 V1 V2 1 0 1 0 0 0 2 101 1 0 1 0 1 0 4

2 m
j "j
105 1 0 1 0 1 0 8 102 0 1 0 1 1 0 16

ij

Sum: mi,j * 2j
wi
14 48 14 48 28 32

104 0 1 0 1 1 0 32

for each row (wi)

Generate 2j

2j

#4. If wi is in ascending order, stop. Otherwise, arrange rows to make Wi ascend.

103 1 1 0 0 0 0

101 1 1 1 0 0 0

105 1 1 1 0 0 0

102 0 0 1 0 1 1

104 0 0 0 1 1 1

D1 M1 V1 V2 D2 M2

V1
V2

M1 D2 V 2

#5 Stop and make Cells and Part families

103 1 1 0 0 0 0

101 1 1 1 0 0 0

105 1 1 1 0 0 0

102 0 0 1 0 1 1

104 0 0 0 1 1 1

D1 M1 V1 V2 D2 M2

DIRECT CLUSTER ALGORITHM

D1 D2 M1 M2 V1 V2 101 1 0 1 0 1 0 102 0 1 0 0 1 0 103 1 0 1 0 1 0 104 0 1 0 1 0 1 105 1 0 1 0 1 0 wi 3 2 3 1 4 1

Step #1.

For

I,

calculate the total no. of positive cells in row, i

wi =

M ij
a ll j

Sort rows in descending order of the wi values

V1 D1 D2 V1 M 1 D2 M2 M2 V2

D1

101 1 1 1 0 0 0 3

102 1 0 0 1 0 0 2

103 1 1 1 0 0 0 3

104 0 0 0 1 1 1 3

105 1 1 1 0 0 0 3

wi 4 3 3 2 1 1 1

No Change No Change

Step #2.

calculate the total # of positive cell in each column, j

j,

wj =

m
alli

ij

Sort columns in ascending order.

V1 D1 M1 D2 M2 V2

101 1 1 1 0 0 0

102 1 0 0 1 0 0

103 1 1 1 0 0 0

104 0 0 0 1 1 1

105 1 1 1 0 0 0

Step #3.

For i = 1 to n, move all columns j where mij = 1 to the left maintaining the order of previous rows.
Observe Elements of Row 1

V1 D1 M1 D2 M2 V2

102 1 0 0 1 0 0

101 1 1 1 0 0 0

103 1 1 1 0 0 0

104 0 0 0 1 1 1

105 1 1 1 0 0 0

Move Column 105 to the left and push column 104 back

For Rows 1,2 & 3: Move the 1s to the left and push the columns with the zeroes back

Observe Elements of Rows 2 & 3

V1 D1 M1 D2 M2 V2

102 1 0 0 1 0 0

101 1 1 1 0 0 0

103 1 1 1 0 0 0

105 1 1 1 0 0 0

104 0 0 0 1 1 1

Move Columns 101, 103 & 105 to the left and push column 102 back

Observe Elements of Row 4

V1 D1 M1 D2 M2 V2

101 1 1 1 0 0 0

103 1 1 1 0 0 0

105 1 1 1 0 0 0

102 1 0 0 1 0 0

104 0 0 0 1 1 1

Move Column 102 to the left and push column 101 back

Observe Elements of Rows 5 & 6

V1 D1 M1 D2 M2 V2

102 1 0 0 1 0 0

101 1 1 1 0 0 0

103 1 1 1 0 0 0

105 1 1 1 0 0 0

104 0 0 0 1 1 1

Move Column 104 to the left and push column 102 back

V1 D1 M1 D2 M2 V2

104 0 0 0 1 1 1

102 1 0 0 1 0 0

101 1 1 1 0 0 0

103 1 1 1 0 0 0

105 1 1 1 0 0 0

Step #4. For j = m to 1, move all rows I, where mij = 1 to the top maintaining the order of the previous columns, wij
Observe Elements of Columns 101, 103 & 105: No Change can be made!!
Observe Elements of Column 102

V1 D1 M1 D2 M2 V2

104 0 0 0 1 1 1

102 1 0 0 1 0 0

101 1 1 1 0 0 0

103 1 1 1 0 0 0

105 1 1 1 0 0 0

Move Row D2 upwards and push row D1 down

Observe Elements of Column 104

V1 D2 M1 D1 M2 V2

104 0 1 0 0 1 1

102 1 1 0 0 0 0

101 1 0 1 1 0 0

103 1 0 1 1 0 0

105 1 0 1 1 0 0

Move Row D2 to the top and push row V1 down

Observe Elements of Column 104

D2 V1 M1 D1 M2 V2

104 1 0 0 0 1 1

102 1 1 0 0 0 0

101 0 1 1 1 0 0

103 0 1 1 1 0 0

105 0 1 1 1 0 0

Move Rows M2 & V2 upwards and push row V1 down

D2 M2 V2 V1 M1 D1

104 1 1 1 0 0 0

102 1 0 0 1 0 0

101 0 0 0 1 1 1

103 0 0 0 1 1 1

105 0 0 0 1 1 1

Step #5.

If current matrix is the same as the previous, stop; else to go 3.

Identify Cells or potential Cells

D2 M2 V2 V1 M1 D1

104 1 1 1 0 0 0

102 1 0 0 1 0 0

101 0 0 0 1 1 1

103 0 0 0 1 1 1

105 0 0 0 1 1 1

Cell #1

Cell #2

Part Family #1

Part Family #2

Production Flow Analysis -SCOPEWe learned two (and probably the most common) methods/algorithms for performing a Production Flow Analysis.
There are a host of other algorithms and methods which are used in Academics and in the Industry. (contd..)

Production Flow Analysis -Organizational ViewProduction Flow Analysis consists of 5 different analyses: 1. Company Flow Analysis 2. Factory Flow Analysis 3. Group Analysis 4. Line Analysis 5. Tooling Analysis

Company Flow Analysis

A Planning technique used for the division of large companies into factory components. It aims to simplify the flow of materials between factories. Uses FROM-TO charts and frequency charts and a flow analysis (similar to the one discussed in slides 29 41). Is not a decision making model, but presents data in a way that decisions can be made based on a companys goal.

CFA (Analysis)

Companys Goals

We get a SCHEME for the division of products and components, machines and facilities into factory sets

Factory Flow Analysis

An attempt is made at this stage to find major groups of departments, and major families of components which can be completely processed in these departments. The Goal is to change factories from process organization to product organization and to minimize interdepartmental material flow

(Contd.. FFA Methodology )

Factory Flow Analysis -Methodology Study and map the existing flow system Identify the dominant material flows between shops (or buildings) Determine the Process Route Number (PRN) for each part Analyze the part by PRN. Combine closely associated processes at departments that complete most of the parts they make If parts are observed to backtrack then such flows are eliminated by minor redeployment of equipment

Factory Flow Analysis -An Example-

Group Analysis
The flows in each of the individual shops (identified by FFA) are analyzed. Operation sequences of the parts that are being produced in a particular shop are analyzed to identify manufacturing cells. Loads are calculated for each part family to obtain the equipment requirements for each cell

Group Analysis
Essentially, while forming and rearranging the PFA matrix (slides 29-41) we were performing Group Analysis. Those same algorithms are also employed in PFA activities other than Group Analysis (namely CFA, FFA etc..) Choice of algorithm or technique that is best suited is, for the most part, a problem specific issue

Line Analysis
A linear or U-layout is designed for the machines assigned to each cell. The routings for each part assigned to the cell and the frequency of use of each routing are used to develop a cell for:
Efficient transport, & Minimum material handling and travel by operators.

Line Analysis Example

Tooling Analysis
A Tooling Analysis helps to schedule the cell by identifying families of parts with similar operation sequences, tooling and setups. It seeks to sequence parts on each machine to sequence all the machines in the cell to reduce setup times and batch sizes. This increases available machine capacity on bottleneck work canters in the cell.

PFA: Assumptions
Each component is equally important in terms of cost Lot size & its associated cost are not directly related to grouping procedure Routing is assumed to be optimal

PFA: Weakness
PFA is suitable mostly for small sized applications, but it has difficulties coping with some large cell formation problems when the Machine-Part Matrix becomes more complex because of problem size

PFA: Advantages
Reduces flow distances Better suited to JIT and pull manufacturing as the overall flow is much straighter Simple and Easy to implement Experience: Lots of Research and Background and support software

Questions?!?
Could you use this for a real-world problem? What problems arise from using PFA?