Cellular LayOut
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Cellular layout is a manufacturing approach that organizes equipment and workstations into cells dedicated to producing families of parts, optimizing production flow in small lots. It leverages group technology to facilitate just-in-time manufacturing, aiming to reduce waste and improve efficiency through better use of resources and employee empowerment. Although it offers several advantages like reduced handling time and enhanced scheduling, challenges include potential issues with cell formation and the need for cross-trained workers.
Cellular LayOut
- 3. FLOW IN A U-CELL • EQUIPMENT AND WORKSTATIONS USED TO PRODUCE ARE ARRANGED TO FACILITATE • CONTINUOUS PRODUCTION FLOW IN SMALL LOTS. Example of Cellular Layout
- 4. CELLULAR LAYOUT • EVERY CELL CONTAINS A GROUP OF MACHINES WHICH ARE DEDICATED TO THE PRODUCTION OF A FAMILY OF PARTS. • ONE OF THE PROBLEMS IS TO IDENTIFY A FAMILY PARTS THAT REQUIRE THE SAME GROUP OF MACHINES. • THESE LAYOUTS ARE ALSO CALLED AS GROUP TECHNOLOGY LAYOUTS.
- 5. CELLULAR LAYOUT • USED TO MAKE PARTS IN JUST-IN-TIME MANUFACTURING • BASED ON GROUP TECHNOLOGY • GROUP TECHNOLOGY (GT): A METHOD OF ORGANIZING PARTS INTO FAMILIES WITH SIMILAR MANUFACTURING REQUIREMENTS • A MANUFACTURING CELL IS CREATED FOR EACH PART FAMILY
- 6. EXAMPLE OF GROUP TECHNOLOGY
- 7. PROCESS FLOW BEFORE THE GROUP TECHNOLOGY
- 8. PROCESS FLOW AFTER THE GROUP TECHNOLOGY
- 10. ONE PIECE FLOW • HANDLING ITEMS ONE AT A TIME ELIMINATES WASTES INHERENT IN BATCH PRODUCTION • AND ENABLES A BALANCED FLOW OF WORK.
- 11. REQUIREMENTS FOR THE CELLS LAYOUT • IDENTIFICATION OF FAMILIES PRODUCTS • A HIGH LEVEL OF TRAINING, FLEXIBILITY AND EMPOWERMENT OF EMPLOYEES • BEING SELF-CONTAINED, WITH ITS OWN EQUIPMENT & RESOURCES
- 12. IMPROVING LAYOUTS USING WORK CELLS
- 13. IMPROVING LAYOUT USING WORK CELLS
- 14. EXAMPLE OF CELLULAR LAYOUT
- 15. CONTINUE • THE PREVIOUS SLIDE SHOWS A FACILITY IN WHICH THREE PARTS A, B, C FLOW THROUGH THE MACHINES. • SOME OTHER PARTS D,E,F,G & H ARE ALSO INCLUDED IN THE NEXT SLIDES. • THE ROWS CORRESPOND TO THE PARTS AND COLUMNS TO THE MACHINES. • JUST BY INTERCHANGING ROWS AND COLUMNS, EVENTUALLY A MATRIX IS OBTAINED WHERE THE “X” MARKS ARE ALL CONCENTRATED NEAR THE DIAGONAL. THIS MATRIX PROVIDES THE CELLS. FOR EXAMPLE, PARTS A, D AND F REQUIRE MACHINES 1, 2, 4, 8 AND 10 WHICH FORMS A CELL.
- 16. EXAMPLE TABLE Parts 1 2 3 4 5 6 7 8 9 10 11 12 A x x x x x B x x x x C x x x D x x x x x E x x x F x x x G x x x x H x x x Machines
- 17. CELLULAR LAYOUT OF THE EXAMPLE Parts 1 2 4 8 10 3 6 9 5 7 11 12 A x x x x x D x x x x x F x x x C x x x G x x x x B x x x x E x x x H x x x Machines
- 18. FINAL VIEW AFTER CELLULAR LAYOUT EACH OF A, B, C NOW VISITS ONLY ONE AREA, MINIMIZING JUMPING 12 12 3 4 5 6 7 8 910 11 A BCRaw materials Cell1 Cell 2 Cell 3 Assembly
- 19. OBJECTIVE OF CELLULAR LAYOUT • ELIMINATION OF WASTE (MUDA) Transportation Inventory Movement Waiting Over Processing Over Production Defects
- 20. CELLULAR LAYOUT ADVANTAGES • REDUCED MATERIAL HANDLING AND TRANSIT TIME • REDUCED SETUP TIME • REDUCED WORK-IN-PROCESS INVENTORY • BETTER USE OF HUMAN RESOURCES • BETTER SCHEDULING, EASIER TO CONTROL AND AUTOMATE • LESS FLOOR SPACE REQUIRED • REDUCED DIRECT LABOR • HEIGHTENED SENSE OF EMPLOYEE PARTICIPATION • INCREASED USE OF EQUIPMENT & MACHINERY • REDUCED INVESTMENT ON MACHINERY & EQUIPMENT
- 21. CELLULAR LAYOUT DISADVANTAGES • SOMETIMES CELLS MAY NOT BE FORMED BECAUSE OF INADEQUATE PART FAMILIES • SOME CELLS MAY HAVE A HIGH VOLUME OF PRODUCTION AND OTHERS VERY LOW. THIS RESULTS IN POORLY BALANCED CELLS • WHEN VOLUME OF PRODUCTION CHANGES, NUMBER OF WORKERS ARE ADJUSTED AND WORKERS ARE REASSIGNED TO VARIOUS CELLS. TO COPE WITH THIS TYPE OF REASSIGNMENTS, WORKERS MUST BE MULTI-SKILLED AND CROSS-TRAINED • SOMETIMES, MACHINES ARE DUPLICATED IN DIFFERENT CELLS. THIS INCREASES CAPITAL INVESTMENT