Group Technology

Job shop production System

Batch production System
Mass production System

GT

Group Technology
Group technology (GT) is a manufacturing philosophy that seeks to
improve productivity by grouping parts and products with similar
characteristics into families and forming production cells with a group of
dissimilar machines and processes.
The group of similar parts is known as part family and the group of
machineries used to process an individual part family is known as machine
cell. It is not necessary for each part of a part family to be processed by
every machine of corresponding machine cell.

Group Technology
Group technology begun by grouping parts into families, based on
their attributes (Geometry, manufacturing process ).
Geometric classification of families is normally based on size and
shape, while production process classification is based on the type,
sequence, and number of operations. The type of operation is
determined by such things as the method of processing, the method
of holding the part, the tooling.
There are three methods that can be used to form part families:
Manual visual inspection
Production flow analysis
Classification and coding
Manual visual inspection involves arranging a set of parts into
groups by visually inspecting the physical characteristics of the
parts.

Manual visual inspection

Part Family 1

Part Family 2

Production flow analysis: Parts that go

through common operations are grouped
into part families.
The machines used to perform these
common operations may be grouped as a
cell, consequently this technique can be
used in facility layout (factory layout)

Production flow
analysis

Rank Order Clustering Algorithm:

Rank Order Clustering Algorithm is a simple algorithm used
to form machine-part groups.
Step 1: Assign binary weight and calculate a decimal weight for
each row.
Step 2: Rank the rows in order of decreasing decimal weight
values.
Step 3: Repeat steps 1 and 2 for each column.
Step 4: Continue preceding steps until there is no change in the
position of each element in the row and the column.

Example #1
Consider a problem of 5 machines and 6 parts. Try to group them by using
Rank Order Clustering Algorithm.

Part Number
Machine ID

A
1

1
1

1
1

D
E

B
C

1
1

Step 1:
Decimal
equivalent

Part Numbers

B.
Wt:

25

24

23

22

21

20

Machine ID

B
C

1
1

Step 2: Must Reorder!

1
1

Rank

23+21 = 10

24+23 = 24

25+22=36

24+23+21 =
26

25+22+20=37

Step 2:
Part Number
1

Machine ID

6
1

Step 3:
Part Number
B. WT. 1
Machine ID
Decimal
equivalent

Rank

24

23

22

21

20

6
1

24+23 22+21= 22+21+ 24+23= 22+20= 4

2 =16
= 24 6
20=7
24
5
1

Step 4: Must Reorder

Back at Step 1:
Part Number
1
B Wt:

25

24

D. Eqv
6

23

22

21

20

1
Order stays the same: STOP!

Rank

25+24+ 23=56

25+24= 48

22+21+ 20 = 7

22+21=6

22+20=5

Example #2
Part Number
1
A

2
1

Machine ID

1
1

1
1

1
1

1
1

Example #2
Step 1: Assign binary weight and calculate a decimal weight for each row

Part Number
1

2 3 4

6
Binary wt. 2

25 24 23

22

21

20

Machine ID

41

20

105

82

40

1
1

1
1 1

Equivalent
Rank
decimal value

Example #2
Step 3: Reorder the matrix according to rank

Part Number

Machine ID

1
1

1
1

1
1
1

Example #2
Step 4: Assign binary weight and calculate a decimal weight for each Column

Part Number
1

C 16

D 8

Binary wt.

Machine ID

A 4

1
1

1
1

E 2

B 1
Equ. Decimal
Value

24

20

1
11

Rank

22

1
3

10

20

Example #2
Step 5: Reorder the matrix according to rank

Part Number

Machine ID

1
1

Example #2
Repeat Step 1&2: Assign binary weight and calculate a decimal weight for each row

Part Number
1 4 2 7 3

Machine ID

6
Binary wt. 2

25 24 23

1 1 1

22

1 1 1

B
Order stays the same:

1
1

21

20

120

70

56

39

Equivalent
Rank
decimal value

Example #2
Repeat Step 4 & 5

Equ. Decimal
Value

24

22

Part Number
2
7
3
1
1
1
1
1
1
1
20 20 11

Rank

Binary wt.
Machine ID

C
D
A
E
B

16
8
4
2
1

1
1
1

4
1
1
1

Order stays the same: STOP!

1
1
10

1
1
3

Voids

Example #2

Exceptional
parts

Part Number

Machine ID

Part family 1: Part Nos. 1, 4, 2 & 7

Machine Cell 1: C, D & A

Part family 2: Part Nos. 3, 5, and 5
Machine Cell 2: E & B

1
1

No. of exceptional Parts: 3

No. of Voids: 5
No. of bottleneck machines: 2(Machines D & E)

Solutions for overcoming this problem?

Duplicate machines
Alternate process plans
Subcontract these operations

Duplicate machines
Part Number

Part Number

No. of exceptional Parts: 3

No. of Voids: 5

1 1 1

D 1

1 1

1 1 1

No. of bottleneck machines:

2(Machines D & E)

1 1 1
1

Machine ID

Machine ID

C 1

4 2 7 3 6 5

1
1

No. of exceptional Parts: 0

No. of Voids: 9
No. of bottleneck machines: 0
No. of duplicate machine: 2(Machines D & E

Alternate process plans

Part Number

Part Number
1

1 1 1

D 1

1 1

1 1 1

1 1 1
1

Machine ID

Machine ID

C 1

4 2 7 3 6 5
C

B
D

1
1

1
1

No. of exceptional Parts: 3

No. of exceptional Parts: 2

No. of Voids: 5

No. of Voids: 3

No. of bottleneck machines:

2(Machines D & E)

No. of bottleneck machines: 2(Machines D & E

Step 1:
Decimal
equivalent

Part Numbers

B.
Wt:

25

24

23

22

21

20

Machine ID

B
C

1
1

1
1

Rank

23+21 = 10

24+23 = 24

25+22=36

24+23+21 =
26

25+22+20=37

Step 1:
Decimal
equivalent

Part Numbers

B.
Wt:

25

24

23

22

21

20

Machine ID

D
E

1
1

Step 2: Must Reorder!

1
1

Rank

23+21 = 10

24+23 = 24

22 +20=5

24+23+21 = 26

25+ 22 +20=37

Step 3:
Part Number
B. WT. 6

Machine ID

24

23

22

21

20

1
1

Decimal
equivalent

23+22=
2 = 16
12

23+22+ 24+20=
21=14 17

24+21
=18

24+20
=17

Rank

Step 4: Must Reorder

Back at Step 1:
Part Number
6
B.
Wt:
Machine ID

25
1

1
24

23

3
22

2
21

Step 2: Must Reorder

Rank

25+24+ 23=56

22+21+ 20 = 7

22+21= 6

22+ 20 = 5

24+23= 24

5
20

D. Eqv

Back at Step 1:
Part Number

Machine ID

B.
WT.

24

23

22

21

20

Decimal
equivalent

24 =
16

24+23= 24+23= 22+21+

24
24
2 0= 7

22+21
=6

22+20
=5

Rank

Step 2: Must Reorder

Part Number
4
B.
Wt:

25

6
24

Machine ID

23

3
22

2
21

1
Order stays the same: STOP!

Rank

25+24+23=56

25+24= 48

22+21+20 = 7

22+21 = 6

22+20= 5

5
20

D. Eqv

Clustering Methods
Using Process Similarity methods:
Create Machine Part Matrices
Compute machine pair-wise similarity Coefficient
comparisons:

Example:
Part Number
Machine ID

A
1

Sij

ij

xij

x jj

here:
xij is # of parts (in matrix) visiting

1
1

D
E

B
C

both machines of the pair

1
1

jj

is # of parts visiting one but not both machines

Computing Similarity Coefficients:

Total number of coefficient is:
[(N-1)N]/2 = [(5-1)5]/2 = 10
For 25 machines (typical number in a small Job Shop): 300 S ijs

1
x
ij
S AB
.33 S
ij
1 2
xij x jj
Part Number
0
S AC
0
1 2 3 4 5 6
04
A
1
1
2
S AD
.67
B
1 1
2 1
C 1
1
D
1 1
1
E 1
1
1

Machine ID

Continuing:
Sij

ij

xij

x jj Part Number
Machine ID

1 2 3 4 5 6
A

1 1

C 1
D
E 1

1
1 1

1
1

Grouping of parts using Clustering Methods

Similarity coefficients of machine pairs
Machine AB
pairs
SC

.33

AC

AD

AE

BC

BD

BE

CD

CE

DE

0.67

0.67

.67

0.67
0.33
0
Dendrogram

Classification and Coding

Coding refers to the process of assigning symbols to the

parts
The symbols represent design attributes of parts or
manufacturing features of part families
Although well over 100 classification and coding systems
have been developed for group technology applications, all
of them can be grouped into three basic types:
Monocode or hierarchical code
Polycode or attribute
Hybrid or mixed code

MONOCODE (HIERARCHICAL CODE)

This coding system was originally developed for biological

classification in 18th century.

In this type of code, the meaning of each character is dependent on

the meaning of the previous character; that is, each character
amplifies the information of the previous character. Such a coding
system can be depicted using a tree structure

Fig. 1 Spur gear

Monocode of Fig. 1:
A-1-1-B-2

hierarchical code for the spur

gear (Fig. 1)

POLYCODE (ATTRIBUTE CODE):

The code symbols are independent of each
other
Each digit in specific location of the code
describes a unique property of the workpiece
it is easy to learn and useful in manufacturing
situations where the manufacturing process have to
be described
the length of a polycode may become excessive
because of its unlimited combinational features

POLYCODE (ATTRIBUTE CODE):

Polycode for the spur gear (Fig. 1): 22213

MIXED CODE (HYBRID CODE):

In reality, most coding systems use a hybrid (mixed) code so that

the advantages of each type of system can be utilized. The first digit
for example, might be used to denote the type of part, such as gear.
The next five position might be reserved for a short attribute code
that would describe the attribute of the gear. The next digit (7th digit)
might be used to designate another subgroup, such as material,
followed by another attribute code that would describe the attributes.