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### Summary of Chapter: Cellular Manufacturing and Flexible Manufacturing Systems
This chapter delves into the principles and applications of cellular manufacturing and flexible manufacturing systems (FMS). It begins by explaining group technology (GT), a manufacturing philosophy that identifies and groups similar parts to exploit their similarities in design and production. Cellular manufacturing, based on GT, organizes production into specialized work cells that focus on part families, enhancing operating efficiencies.
The chapter details the identification of part families through visual inspection, production flow analysis (PFA), and parts classification and coding. It highlights the benefits of GT, such as reduced material handling, simplified production scheduling, and improved worker satisfaction.
Flexible Manufacturing Systems (FMS) are introduced as highly automated GT machine cells capable of processing various part styles simultaneously. The chapter discusses the components of FMS, including CNC machines, material handling systems, and integrated computer controls. It also outlines the criteria for a system to be considered flexible, such as the ability to process different part styles in a non-batch mode and respond to production schedule changes.
The integration of FMS components and various layout types (in-line, loop, ladder, open field, and robot-centered cell) are covered, emphasizing the importance of software and control functions in an FMS.
### Choose Questions and Answers
1. **What is group technology in manufacturing?**
- **Answer:** Group technology is a manufacturing philosophy where similar parts are identified and grouped together to take advantage of their similarities in design and production.
2. **Define cellular manufacturing.**
- **Answer:** Cellular manufacturing refers to the use of work cells that specialize in producing families of parts or products in medium quantities. 3. **What is a part family?** - **Answer:** A part family is a group of parts that possess similarities in geometric shape and size, or in the processing steps used in their manufacture.
4. **List the methods for identifying part families.**
- **Answer:** The methods include visual inspection, production flow analysis (PFA), and parts classification and coding.
5. **What are the benefits of using a classification and coding system for parts?** - **Answer:** Benefits include quick retrieval of part design drawings, reduced design duplication, promoted design standardization, improved cost estimating, and facilitated computer-aided process planning.
6. **What is a flexible manufacturing system (FMS)?**
- **Answer:** An FMS is a highly automated GT machine cell that consists of a group of processing stations, interconnected by an automated material handling and storage system, and controlled by an integrated computer system.
7. **What criteria must a manufacturing system meet to be considered flexible?**
- **Answer:** It must process different part styles in a non-batch mode, accept changes in production schedules, respond to equipment malfunctions, and accommodate new part designs.
8. **What are the types of FMS layout?**
- **Answer:** Types include in-line, loop, ladder, open field, and robot-centered cell.
9. **Describe the composite part concept in group technology.**
- **Answer:** The composite part is a hypothetical part that includes all design and manufacturing attributes of a part family, allowing a production cell to make any member of the family by omitting operations not needed for specific parts.
10. **What are the potential benefits of machine cells and group technology?** - **Answer:** Benefits include reduced material handling, simplified production scheduling, reduced manufacturing lead time, reduced work-in-process, and improved worker satisfaction.
### Workout Questions and Answers
1. **Explain how cellular manufacturing minimizes the disadvantages of batch production.**
- **Answer:** Cellular manufacturing groups similar parts into work cells, allowing for specialized and efficient production, which reduces the need for frequent machine setups and long production runs associated with batch production.
2. **Describe the process of production flow analysis (PFA).**
- **Answer:** PFA involves data collection of part numbers and operation sequences, sorting process routings, displaying processes in a PFA chart, and performing cluster analysis to identify and group similar machine sequences.
3. **What role does visual inspection play in identifying part families?**
- **Answer:** Visual inspection, the least sophisticated and least expensive method, involves grouping parts based on observed similarities in their geometric shape and manufacturing processes.
4. **How does an FMS respond to equipment malfunctions?**
- **Answer:** An FMS is designed to respond gracefully to equipment malfunctions, often by rerouting tasks to other functioning machines to maintain production flow.
5. **Why is the Opitz classification system significant in manufacturing?**
- **Answer:** The Opitz system is one of the first published classification and coding schemes, widely recognized for its comprehensive approach to encoding both design and manufacturing attributes of parts.
6. **Illustrate the benefits of standardizing tooling and fixturing in group technology.**
- **Answer:** Standardization reduces setup times, allows for more consistent quality, simplifies maintenance, and reduces the inventory of tooling and fixtures. 7. **What are the differences between an FMS and an FMC?** - **Answer:** An FMS typically consists of four or more machines and is designed for higher flexibility and automation, whereas an FMC includes three or fewer machines and might be less complex.
8. **Explain the ladder layout type in FMS.**
- **Answer:** In the ladder layout, workstations are arranged in a linear sequence with branching paths, allowing parts to move in various directions, enhancing flexibility in processing sequences.
9. **Discuss the significance of automated material handling in an FMS.**
- **Answer:** Automated material handling systems in an FMS enhance efficiency by reducing manual labor, speeding up the movement of parts, and integrating with CNC machines for seamless production flow.
10. **How does grouping parts into families improve cost estimating?** - **Answer:** Grouping parts into families allows for more accurate cost estimates based on standardized processing steps and shared resources, leading to better financial planning and pricing strategies.
