Cellular Manufacturing and Plant Layout http:www'managementsupport'com

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Cellular Manufacturingand Plant Layout
http//www.managementsupport.com
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Outline

• Fundamentals of layout
• Process
• Product
• Fixed
• Hybrid
• Cellular Manufacturing
• Characteristics
• Implementing Cells
• Part Families
• Production Flow Analysis

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Product Layout
G
D
L
M
Part 1
A
A
Receiving
Part 2
D
M
Shipping
L
Part 3
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Empowered Employees in Cells

• Goals and tracking charts are maintained and
  posted.
• Problems are solved through daily cell meetings
  and problem solving teams.
• The inventory management system is a KANBAN
  Demand Pull instead of a work order/kit picking
  system.
• Cells are responsible for planning, scheduling
  and expediting directly with vendors.
• They establish and maintain a KANBAN system with
  the vendors.

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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

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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

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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