GROUP TECHNOLOGY
Group technology is a manufacturing philosophy in which
similar parts are identified and grouped together to take adva
ntage of their similarities in manufacturing and design.
Similar parts are arranged into part families, where each
part family possesses similar design and/or manufacturing
characteristics.
Grouping the production equipment into machine cells,
whereeach cell specializes in the production of a part family,
is called cellular manufacturing.
Part family
A Part family is a collection of parts which are
similar either because of geometric shape (or) size
(or) because similar processing steps are required
in their manufacture.
The parts within a family may be different, but
their similarities are close
Part design attributes
Basic external shape
Major dimensions
Basic internal shape
Minor dimensions
Length/diameter ratio
Tolerances
Material type
Surface finish
Part function
Part manufacturing attributes
Major process
Operation sequence
Minor operations
Production time
Major dimensions
Batch size
Length/diameter ratio
Annual production
Surface finish
Fixtures needed
Machine tools
Cutting tools
Similarities in design
Similarities in manufacturing
Grouping parts into families
[Link] inspection
[Link] classification and coding
[Link] Flow Analysis(PFA)
Benefits of Parts classification and
coding
It facilitates the formation of part families and machine
cells
It permits quick retrieval of designs, drawings and
process plans
It facilitates accurate estimation of machine tool
requirements
It reduces setup time and design time
It helps in production, planning and scheduling
procedures
It provides for better machine tool utilization
Process type layout
Group Technology Layout
Coding structures
Hierarchical
Chain type
Hybrid
Parts classification and coding systems
Three types of parts classification and coding
systems
[Link] system
2. MICLASS system
3. CODE system
Opitz classification system
The Opitz coding system uses the following digit sequence:
12345 6789 ABCD
The basic code consists of nine 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
describe the primary design attributes of the part.
Opitz classification system
The next four digits, 6789, constitute the “supplementary
code” and describe the manufacturing attributes
(dimensions, work material, starting raw work
piece shape and accuracy).
The extra four digits, ABCD, are referred to as the
"secondary code" and are intended to identify the
production operation type and sequence.
In the form code, the first digit identifies whether the
part is a rotational (or) a non-rotational part.
Basic structure of opitz system
Form code
Example
The MICLASS System
The MICLASS system was developed and helps to
automate and standardize a number of design, production,
and management functions.
These are:
Standardization of engineering drawings
Retrieval of drawings according to classification number
Standardization of process routing
Automated process planning
Selection of parts for processing on particular groups of
machine tools
The MICLASS System
The MICLASS classification number can range
from 12 to 30 digits.
The first 12 digits are a universal code that can be
applied to any part.
Next 18 digits can be used to code data that are
specific to the particular company .
For example,
Lot size, piece time, cost data, and
operation sequence might be included.
The MICLASS System
The workpart attributes coded in the first 12
digits of the MICLASS number are as follows:
1st digit- Main shape
2nd and 3rd digits -Shape elements
4th digit -Position of shape elements
5th and 6th digits- Main dimensions
7th digit -Dimension ratio
8th digit- Auxiliary dimension
9th and 10th digits -Tolerance codes
11th and 12th digits -Material codes
The MICLASS System
User codes the parts by responding to a series of
questions asked by the computer and most
questions are yes/no type
The CODE system
Its most universal application is in design engineering for retrieval
ofpartdesigndata, but it also has applications in manufacturing pro
cess planning, purchasing, tool design, and inventory control.
The CODE number has eight digits. For each digit there are 16
possible values (0 through 9 and A through F) which are used to
describe the part's design and manufacturing characteristics.
The first digit position indicates the basic geometry of the part and
is called the Major Division of the CODE system.
The CODE system
This digit would be used to specify whether the shape
was a cylinder, flat piece, block.
The interpretation of the remaining seven digits depends
on the value of the first
digit, but these remaining digits form a chain-
type structure.
Hence the CODE system possesses a hybrid structure
The CODE system
2nd &3rd digits provide additional information related to
basic geometry & principal manufacturing process for the
part.
4th,5th,6th digits specify secondary manufacturing
processes such as threads, grooves, slots.
7th,8th digits are used to indicate the overall size of the
part(e.g. length, diameter)
Production Flow Analysis (PFA)
It is a method for identifying part
families and associated machine groupings that uses the
information contained on process plans rather than on
part drawings.
Work parts with identical or similar process plans are
classifiedinto part families. These families can then be
used to form logical machine cells in a group technology
layout.
(PFA)-Procedure
The procedure of Production flow analysis (PFA) consists of the
following steps:
1. Data Collection. The minimum data needed in the analysis are the
part number and operation sequence, which is obtained from process
plans.
2. Sortation of process plans. A sortation procedure is used to group
parts with identical process plans.
3. PFA Chart. It is referred to as machine part incidence matrix.
(PFA)-Procedure
[Link].
From the pattern of data in the PFA chart, related
groupings are identified and rearranged into a new pattern
that brings together groups with similar machine
sequences.
Rank Order Clustering (ROC) Algorithm
The ROC algorithm is applied by alternately
re-arranging rows (machines) and columns (parts)
until no further re-arrangement is possible. In this
algorithm both machines and parts are grouped
simultaneously.
Parts are arranged into part families & Machines
are arranged into machine groups
Benefits of GT
Product design benefits
Tooling and setups
Materials handling
Production and inventory control
Employee satisfaction
Process planning procedures
