Manufacturing Cells

Ing. Borys Culqui MSc.

April 2020

20 de abril de 2020 2 HR

CONTENIDO
1 Celdas de SEMAN HORAS
Manufactura A
1 Parámetros de Diseño 1 2
2 Selección de Componentes 1 2
3 Simulación de la Celda Mediante Software 2 2

DESIGN PARAMETERS
Definitions
Production System
A production system is a collection of people, equipment and procedures organized to
perform the manufacturing operations of a company.

Figure 1. Production System

Manufacturing System
A manufacturing system is a collection of integrated equipment designed for some special
mission, such as machining a defined part family or assembling certain product. Include
people.
Manufacturing Process
Application of physical and chemical process to alter the geometry properties and/or
appearance of a given started material to make parts or a whole product. This definition
includes assembly process.

Figure 2. Manufacturing Process

Types of process
 Services process
 Manufacturing process - VA – NVA
o NVA Reducir al minimo
 Management process

Work station:
It is a location in the factory where some well-defined task or operation is
accomplished by an automated machine, a worker and machine combination, or a
worker using hand tools or portable tools.
Area de produccion
Product ingreso y terminado
24 de abril de 2020 1 (REAL 1.5) HR

Clasification of A Manufacturing System

The factors are:
a) Types of operations performed.
b) Number of workstations and system layout.
c) Level of automation.
d) Part or product variety.

Types of Operation Performed

a) Processing operations
b) Assembly operations

Number of Workstations
The individual stations in a manufacturing system can be identified by the subscripts, where
i:1,2, ... ,n.
  Type I: Single station
 Type II: Multiple stations with variable routing
 Type III: Multiple stations with fixed routing.

Figure 3 P-Q chart the types of manufacturing systems in our

Level of Automation

There are three levels:

 Manual (M)
 Fully automated (A)
 Hybrid (H)

Part or Product Variety

a) Single model: parts identical
b) Batch model: changeover in physical setup
 c) Mixed model: without changeover in setup
Table 1 Three types of Manufacturing System According to their Capacity to deal with Product Variety
System Type Symbol Typical Product Variety Flexibility
Single Model S No product Variety None required
Batch model B Hard product Variety typical* Most required
Mixed model X Soft product variety typical* Some required
*Hard and soft product variety are defined in Chapter 1
Hard product variety is when the products differ substantially

MANUFACTURING CELLULAR SYSTEM

Group technology: is a manufacturing philosophy in which similar parts are identified and
grouped together to take advantage of their similarities in design and production.
The parts can be grouped into part families. So a part family is a collection of parts that are
similar either because of geometric shape and size or because similar processing steps are
required in their manufacture.
Cellular manufacturing is an application of group technology in which dissimilar machines
or processes have been aggregated into cells, each of which is dedicated to the production of a
part or product family or a limited group of families.

Figure 4 Single Station and process type plant layout

Lotes
Ordenes de produccion A1, B1, A2, C1,
Familia 1
Celda 1
pie
Familia 2
pie

pie

Celda 2

pie

Figure 5 cellularmanufacturing Group Technology layout

Planificación
Demanda del cliente (takt time min/unid)
Ordenes producción 1000 unid de familia 1,
Factor de mezcla, Pa=20%, Pb=30%, Pc=50%

Ejemplo
Una empresa va a fabricar 1000 engranajes (A modulo 2 z=15, B modulo 2 z=20) el cliente.
Tc turn = 1 min
Tc mill = 2 min
Tc drill = 1 min
Tc asby = 0.5 min
MLT = 4500 min
En que tiempo se entregan 20 unidades mediante manufactura single station y manufactura
celular

27 de abril de 2020 2 hr
OBJECTIVES

The objectives in cellular manufacturing are similar to those of group technology:

 To shorten manufacturing lead times, by reducing setup, work part handling, waiting
times, and batch sizes.
 To reduce work-in-process inventory. Smaller batch sizes and shorter lead times
reduce WIP.
o WiP = WIPa + WIPb + WIPc + ….
 To improve quality. This is accomplished by allowing each cell to specialize in
producing a smaller number of different parts. This reduces process variations.
 To simplify production scheduling. The similarity among parts in the family reduces
the complexity of production scheduling. Instead of scheduling parts through a
sequence of machines in a process-type shop layout, the parts are simply scheduled
though the cell.
 To reduce setup times. This is accomplished by using group tooling (cutting tools, jigs,
and fixtures) that have been designed to process the part family, rather than part
tooling, which is designed for an individual part. This reduces the number of individual
tools required as well as the time to change tooling between parts.

MANUFACTURING CELLS COMPONENTS

A cell manufacturing system consists of several components.
1) Production machines
2) Material handling system
3) Computer control system
4) Human worker

Production machines:
Include: machines, tools, fixtures, hardware.

Types:
a. Manually operated
Worker provides control
b. Semi-automated:
Machine performs a portion of the work cycle under some form of control program
 Worker tends machine
c. Fully automated:
No human attention for periods longer than one work cycle
Worker load raw material

Material handling system

Functions:
a. Loading work unit
Move part since source in work station
a. Positioning work unit
Workholder is a device that accurately locates, orients, and clamps the part for the
operation, like: jigs, fixture, chuck.
b. Unloading work unit
 Place in containers
c. Transporting work unit
 Move parts between workstation, manual
 Fixed route
 Variable route: job shop, GT, FMS
d. Temporary storage

Computer control system

Computer systems is required to control the automated and semi-automated equipment
and to participate in the overall coordination and management of the manufacturing
system.

Human worker
Human resource performs some of all the value added work that is accomplished on the
part. Human workers are direct labor.
ANALYSIS AND CELL SIMULATION

El análisis de una celda de manufactura consiste en la determinación de que partes de la que

fabrica la empresa están formando familias y que maquinas se pueden agrupar como celda
que produce una determinada familia. Además, también debe definirse cuál es el arreglo de
las maquinas o la secuencia de las mismas en la celda.
Hay dos métodos que se pueden usar para lograr el objetivo, los mismos son.
 Grouping Parts and Machines
o La empresa tiene productos, A, B, C, D E F G H I………Z
 Familia 1 compuesta por A-B-C, se produce en la celda 1 (1-5-20)
 Familia 2 compuesta por D-F-H, se produce en la celda 2 (2-8-15)
 ….
 Arranging Machines in a GT Cell
 Secuencia de maquina en la celda 1 (materia -> 2 -> 1 -> 5 -> pt)

A continuación se describe cada método.

1.1. Grouping Parts and Machines
The rank order clustering technique, first proposed by King (is specifically applicable in
production flow analysis).
The problem addressed here is to determine how machines in an existing plant should be
grouped into machine cells.
Starting with the initial part-machine incidence matrix the algorithm consists, of the
following steps:
a) In each row of the matrix. Read the series of 1’s and 0’s (blank entries =0’s) from left to
right as a binary number. Rank the rows in or der of decreasing value. In case of a tie,
rank the rows in the same order as they appear in the current matrix.
b) Numbering from top to bottom, is the current order of rows the same as the rank order
determined in the previous step? If yes, go to step 7, if no, go to the following step.
c) Reorder the rows in the part-machine incidence matrix by listing them in decreasing
rank order, starting from the top.
d) In each column of the matrix. Read the series of 1's and O's (blank entries = (j's) from
top to bottom as a binary number. Rank the columns in order of decreasing value, In
case of a tie. Rank the columns in the same order as they appear in the current matrix.
e) Numbering from left to right, is the current order of columns the same as the rank order
determined in the previous step? If yes. Go to step 7. If no. Go to the following step.
f) Reorder the columns in the part-machine incidence matrix by listing them in decreasing
rank order, starting with the left column. Go to step I.
g) Stop.

Example
Table 2 Possible Code Numbers Indicating operations and/or Machines for Sortation in Production Flow
Analysis (Highly Simplified)
Operation or Machine Code
Cutoff 01
Lathe 02
Turret lathe 03
Mill 04
Drill: Manual 05
NC drill 06
Grind 07

Figure 6

Figure 7
 Figure 8

CEL L 1 FAMILIA 1

Figure 9
Disadvantages
The weakness of production flow analysis is that the data used in the technique are
derived from existing production route sheets. In all likelihood, these route sheets have been
prepared by different process planners, and the routings may contain operations that are no
optimal, illogical, or unnecessary. Consequently, the final machine groupings obtained in the
analysis may be suboptimal.

1.1. Arranging Machines in a GT Cell

The next problem is to organize the machines into the most logical arrangement (sequence
of machines).
There are two methods suggested by Hollier. They are intended to arrange the machines in an
order that maximizes the proportion of in-sequence moves within the cell
Hollier Method 1
The first method uses the sums of flow "From" and "To" each machine in the cell. The
method can be outlined as follows:
a. Developed From-To chart from part routing data. The data contained in the chart
indicate numbers of part moves between the machines (or workstations) in the
cell.
b. Determine the "From" and "To" sums for each machine. This is accomplished by
summing all of the "From" trips and "To" trips for each machine (or operation).
The "From" sum for a machine is determined by adding the entries in the
corresponding row, and the "To" sum is found by adding the entries in the
corresponding column.
c. Assign machines to the cell hosed on minimum "From" or "To" sums. The
machine having the smallest sum is selected. If the minimum value is a "To"
sum, then the machine is placed at the beginning of the sequence. If the
minimum value is a "From" sum, then the machine is placed at the end of the
sequence. Tie breaker rules:
a) If a tie occurs between minimum "To" sums or minimum "From" sums, then
the machine with the minimum "From/To" ratio is selected.
b) If both "To" and "From" sums are equal for a selected machine it is passed
over and the machine with the next lowest sum is selected.
c) If a minimum "To" sum is equal to a minimum "From" sum, then both
machines are selected and placed at the beginning and end of the sequence,
respectively.
d. Reformat the From-To chart. After each machine has been selected, restructure
the from-To chart by eliminating the row and column corresponding to the
selected machine and recalculate the "From" and "To" sums. Repeat steps 3 and
4 until all machines have been assigned.
Ejemplo
Suppose that four machines. 1, 2.3, and 4 have been identified as belonging in a GT machine
cell. An analysis of 50 parts processed on these machines has been summarized in the From-To
chart of Table. Additional information is that '50 parts enter the machine grouping at machine
3,20 parts leave after processing at machine 1, and 30 parts leave after machine 4. Determine
a logical machine arrangement using Hollier Method 1.
Table 3 From-To Chart for Example
To: 1 2 3 4
From: 1 0 5 0 25
2 30 0 0 15
3 10 40 0 0
4 10 0 0 0

Table 4 From To Chart for example

To: 1 2 3 4
 From: 1 0 5 0 25
2 30 0 0 15
3 10 40 0 0
4 10 0 0 0

Table 5 From and to Sums for example

To: 1 2 3 4

From: 1 0 5 0 25
2 30 0 0 15
3 10 40 0 0
4 10 0 0 0

“To” sums 50 45 0 40

Table 6 From and Sums for example. Second Iteration with Machine 3 Removed
To: 1 2 4

From: 1 0 5 25
2 30 0 15
4 10 0 0

“To” sums 40 5 40

Table 7 From to Sum for Example: Third Iteration with Machine 2 Removed
To: 1 4

From: 1 0 25
4 10 0
“To” sums 10 25
Hollier Method 2
a. Develop the From-To chart. This is the same step as in Hollier Method 1.
b. Determine the From/To ratio for each machine. This is accomplished by
summing up all of the "From" trips and "To" trips for each machine (or
operation). The "From" sum for a machine is determined by adding the entries in
the corresponding row, and the "To" sum is determined by adding the entries in
the corresponding column. For each machine, the From/To ratio is calculated by
taking the "From" sum for each machine and dividing by the respective "To"
sum.
c. Arrange machines in order of decreasing From/To ratio. Machines with II high
From/To ratio distribute work to many machines in the cell but receive work
from few machines. Conversely, machines with a low From to ratio receive
more work than they distribute. Therefore, machines are arranged in order of
descending Prom/to ratio. That is, machines with high ratios are placed at the
beginning of the work flow, and machine, with low ratios are placed at the end
of the work flow. In case of a tie, the machine with the higher "From" value is
placed ahead of the machine with a lower value.
Table 8 From-To Sums and From/To Ratios for Example
To: 1 2 3 4 “From” Sums From/To
 From: Ratio
1 0 5 0 25 30 0.60
2 30 0 0 15 45 1.0
3 10 40 0 0 50 ∞
4 10 0 0 0 10 0.25

“To” 50 45 0 40 135
sums

Diagrama de flujo

Figure 10 Diagrama de flujo de ejercicio

1.2. Performance Measures

(a) Percentage of in-sequence moves
(b) Percentage of bypass moves
(b) Percentage of backtracking moves
INDEX
CONTENIDO..................................................................................................................................1
DESIGN PARAMETERS..................................................................................................................1
Definitions................................................................................................................................1
Production System...............................................................................................................1
Manufacturing System.........................................................................................................2
Manufacturing Process.........................................................................................................2
Types of process...................................................................................................................2
Work station:........................................................................................................................2
Clasification of A Manufacturing System..................................................................................2
MANUFACTURING CELLULAR SYSTEM.........................................................................................4
Objectives.....................................................................................................................................6
MANUFACTURING CELLS COMPONENTS.....................................................................................6
ANALYSIS AND CELL SIMULATION................................................................................................7
1.1. Grouping Parts and Machines..................................................................................7
1.2. Arranging Machines in a GT Cell.............................................................................10
1.3. Performance Measures..........................................................................................13