UNIT-III - GROUP TECHNOLOGY AND FMS

PART-A
1. Define group technology (GT)?
Group technology is a manufacturing philosophy to increase production efficiency by
grouping a variety of parts having similarities of shape, dimension, and/or process route.
2. State the role of GT in CAD/CAM integration.
 GT applications provide a common database for effective integration of CAD and CAM,
which leads to successful implementation of CIM.
 To integrate the CAD and CAM, it is needed to integrate the information used by all
department in a shop such as design, manufacturing, quality, etc.,
3. What is a part family?
Part family is defined as collection of parts which are similar either in geometric shape
and size or in the processing steps required in their manufacture.
4. List the general methods used for grouping parts into part families.
1. Visual inspection
2. Parts classification and coding system
3. Production flow analysis
5. List design attributes and manufacturing attributes.
Design Attributes:
1. Shape: The geometric form of the part, including basic profiles (e.g.,
cylindrical, rectangular).
2. Size: Dimensions of the part, such as length, width, height, or diameter.
3. Material: The type of material used (e.g., steel, aluminum, plastic) based on
design requirements.
4. Tolerances: Precision and allowable variation in part dimensions or geometry.
5. Surface Finish: Required smoothness or texture of the part’s surface.
6. Functionality: The intended use or performance characteristics of the part.
7. Weight: The mass of the part, which affects performance and material selection.
Manufacturing Attributes:
1. Manufacturing Process: The processes required to make the part (e.g.,
casting, machining, welding).
2. Production Volume: The number of parts to be produced, affecting process
selection and tooling.
3. Material Handling: How the part is moved through different stages of production.
4. Machinability: The ease with which the material can be cut, shaped, or finished.
5. Tooling Requirements: The type of tools or equipment needed for production.
6. Lead Time: The time required to produce the part, including setup and
processing time.
7. Setup and Changeover Time: The time needed to prepare machines and switch
between different part productions.
6. What are the three basic code structures used in GT applications?

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 a) Hierarchical structure
b) Chain or Attribute structure
c) Hybrid structure
7. What is the main difference between hierarchical codes and attribute code structures?
In hierarchical structure, the interpretation of each symbol in the sequence depends on the
value of preceding symbols.
Whereas in attribute/polycode structure, the interpretation of each symbol in the sequence
does not depend on the value of preceding symbols.
8. List any six coding systems that are widely recognized in industries.
1. OPITZ system.
2. KK – 3 system.
3. DCLASS system.
4. Multi- class system.
5. CODE system
6. RNC – 6 digits Mono code system.
9. What do you mean by form code and supplementary code in Opitz classification system?
The Opitz coding system uses alpha numeric symbols to represent the various attributes
of a part.
The Opitz coding scheme uses the following digit sequence: 12345 6789 ABCD
 The first five digits (12345) code the major design attributes of a part and are called
the “form code”.
 The next four digits (6789) are for coding manufacturing related attributes and are
called the “supplementary code”.
 The letters (ABCD) code the production operation and sequence and sequence and
are referred to as the “secondary code”.
10. List the factors to be considered in selection of coding system.
a) Objective of the classification system
b) Robustness- capability of handling all parts now being sold or planned to sold by
the firm.
c) Expandability- ability to cope up with future demands.
d) Automation- for computer use.
11. Mention the benefits of GT.
 Reduced setup time
 Improved production control
 Reduced inventory
 Standardization of processes
12. Define Flexible manufacturing system
FMS is an automated production system that uses programmable machines, robots, and
material handling equipment, all controlled by a central computer, to efficiently produce a variety
of products with minimal downtime and reconfiguration. It enables rapid adaptation to changes in
product types and production volumes.
13. List the components in a Flexible Manufacturing System
a. Workstations
b. Material Handling System
c. Central Control System
d. Storage System
e. Tooling and Fixtures
f. Communication System
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 14. What are the FMS layout configurations
FMSs can be divided into five categories
1) In-line layout
2) Loop layout
3) Ladder layout
4) Open field 1ayout
5) Robot-centered cell
15. What arc the functions of computers in FMS?
The functions of computers in FMS
1. Workstation control
2. Distribution of control instructions to workstations
3. Production control
4. Traffic control
5. Shuttle control
6. Work piece monitoring
7. Tool control
8. Performance monitoring and reporting
9. Diagnosis
16. Define cellular manufacturing.
Cellular manufacturing is an application of group technology in which dissimilar
machines or processes have been aggregated in to cells, each of which is dedicated to the
production of a part or product family or a limited group of families.
17. List any four reasons for implementing cellular manufacturing.
 Increased machine utilization
 Fewer machines required
 Reduction in factory floor space required
 Greater responsiveness to change
 Reduced inventory requirements
 1ower manufacturing lead times
 Reduced direct labour requirements and higher labor productivity
 Opportunity for unattended production
18. List any four design considerations guiding the cell formation.
 Parts/products to be fully completed in the cell
 Higher operator utilization
 Fewer operators than equipment.
 Balanced equipment utilization in the cell
19. What is a composite part?
A composite part in FMS is a theoretical model that represents the entire range of
features common to all parts within a specific part family. It's a hypothetical part that
encompasses the maximum design and manufacturing attributes found in the group, serving as a
basis for cell design and ensuring efficient production planning and scheduling.
20. How can you classify a manufacturing cell?
(i) Single machine cell
(ii) Group machine cell with material handling
(iii) Group machine cell with semi-integrated
handling (iv)Flexible manufacturing cell or systems
21. What is meant by a key machine?
In a GT machine cell, a certain machine is referred as the key machine or bottleneck

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 machine: (i) when that machine is more expensive to operate than the other machines in the cell;
or (ii) when that machine performs certain critical operations in the shop floor.

22. What are the exceptional elements? How they can be eliminated/reduced?
Though it is desired to create the mutually independent cells with no intercell movement,
it may not always be practical to achieve this. In practice, some parts needs to be processed in
more than one cell. These are known as "exceptional" elements and the machines processing them
are known as "bottleneck" machines.
The problem of exceptional elements can be eliminated/reduced by:
(1) Duplication of machines,
(ii) Generating alternative process plans, and
(iii) Subcontracting these operations.
PART B & C
1. Explain part family? And also explain parts classification and coding method.
Group Technology Defined:
 An approach to manufacturing in which similar parts are identified and grouped together
in order to take advantage of their similarities in design and production
 Similarities among parts permit them to be classified into part families
 In each part family, processing steps are similar
 The improvement is typically achieved by organizing the production facilities into
manufacturing cells that specialize in production of certain part families
Part Family
A group of parts that possess similarities in geometric shape and size, or in the processing
steps used in their manufacture. Two parts that are identical in shape and size but quite different
in manufacturing:

(a) 1,000,000 units/yr, tolerance = ±0.010 inch, 1015 CR steel, nickel plate
(b)100 units/yr, tolerance = ±0.001 inch, 18-8 stainless steel

Ten parts that are different in size and shape, but quite similar in terms of manufacturing.
All parts are machined from cylindrical stock by turning; some parts require drilling and/or

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 milling
Ways to Identify Part Families:
1. Visual inspection - using best judgment to group parts into appropriate families, based
on the parts or photos of the parts

2. Production flow analysis - using information contained on route sheets to classify parts
3. Parts classification and coding - identifying similarities and differences among parts and
relating them by means of a coding scheme
Parts Classification and Coding
Most classification and coding systems are one of the following:
 Systems based on part design attributes
 Systems based on part manufacturing attributes
 Systems based on both design and manufacturing attributes
Part Design Attributes:
o Major dimensions
o Basic external shape
o Basic internal shape
o Length/diameter ratio
o Material type
o Part function
o Tolerances
o Surface finish
Part Manufacturing Attributes:
o Major process
o Operation sequence
o Batch size
o Annual production
o Machine tools
o Cutting tools
o Material type
Three structures used in classification and coding schemes:
(i) Hierarchical structure, known as a mono-code, in which the interpretation of each
successive symbol depends on the value of the preceding symbols.
In a hierarchical classification and coding structure, parts are classified in a tree-like
arrangement with multiple levels of categorization. This system organizes parts from general

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 categories at the top to more specific subcategories at lower levels.
Characteristics:

o Tree-like classification: Each part is categorized under a broad parent category, which is
divided into more specific subcategories as you go down the hierarchy.
o Levels of detail: The deeper you go into the hierarchy, the more specific the classification
becomes.
o One-to-many relationship: Each parent category can have multiple subcategories, but
each subcategory belongs to only one parent.

Advantages:
 Easy to understand and navigate, especially when parts are logically grouped by broad
categories.
 Provides a structured way to break down complex categories into simpler, more specific
ones.
Disadvantages:
 Rigid structure makes it difficult to handle parts that could belong to multiple categories.
 Changes or additions at higher levels may require significant reorganization.
(ii) Chain-type structure, known as a Polycode or Attribute code, in which the interpretation of
each symbol in the sequence is always the same; it does not depend on the value of preceding
symbols.
Advantages:
 Simple to implement and maintain, especially in environments where parts are produced or
used in a linear process.
 Easy to expand since new parts just get the next number in the sequence.
Disadvantages:
 Not suitable for complex classification where parts have multiple attributes or
relationships.
 The linear structure can lack flexibility for categorizing parts with overlapping functions or
uses.

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 (iii) Mixed-mode structure, which is a hybrid of the two previous codes. The best features of
both hierarchical and chain-type structures are combines together. This hybrid system allows for
more flexibility by integrating both hierarchical grouping and sequential numbering,
accommodating complex parts that may not fit neatly into a single category or sequence.

Advantages:
 Allows for more flexibility and complexity in parts classification, making it suitable
for large systems with diverse components.
 Accommodates multiple attributes (e.g., material, function, size) without the rigidity
of purely hierarchical or chain-based systems.
Disadvantages:
 More complex to manage and maintain than simple hierarchical or chain structures.
 Potential for confusion if not well-documented or consistently applied.

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 2. Explain optiz classification system.
Though more than 100 coding systems are available, Some important coding
systems are
a) Opitz classification system – the University of Aachen in Germany
b) Brisch System – (Brisch-Birn Inc.)
c) CODE (Manufacturing Data System, Inc.)
d) CUTPLAN (Metcut Associates)
e) DCLASS (Brigham Young University)
f) MultiClass -MCLASS (OIR: Organization for Industrial
g) Part Analog System (Lovelace, Lawrence & Co., Inc.)
Basic Structure of the Opitz Parts Classification and Coding System:

Form code (digits 1-5) for rotational parts in the Opitz coding system

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 The Opitz Parts Classification and Coding System is a widely used method for
classifying and coding mechanical parts based on their design and manufacturing attributes.
Developed by H. Opitz in the 1960s, it is commonly applied in manufacturing, particularly in
group technology (GT), to group similar parts for efficient production and inventory
management.
The Opitz system uses a multi-digit code to represent various features of a part, including
its geometry, shape, size, and production requirements. By grouping similar parts, the system
enables companies to optimize processes like production planning, tool design, and inventory
control.
Structure of the Opitz Classification System
The Opitz system consists of two main sections: the basic code and the supplementary
code.
1) Basic Code
The basic code is the core of the Opitz system and consists of 5 to 9 digits. It is designed
to classify the main geometrical and technological features of a part. Each digit or group of digits
in the basic code represents a specific characteristic of the part, such as shape, dimensions, and
manufacturing methods. The basic code is usually broken down as follows:
Digit Position Description
1st Digit Part’s Shape (external shape)
2nd Digit Main Dimension Ratios (length to diameter, etc.)
3rd Digit Secondary Shape Features (e.g., holes, steps)
4th Digit Shape of Machined Surfaces
5th Digit Shape Features or Modifications
6th–9th Digits Production-specific Information (optional)
The breakdown of each digit's meaning is specific to the type of part being classified. For
example:
 1st Digit (Shape) might classify the part as rotational (e.g., shafts, cylindrical parts) or
prismatic (e.g., plates, blocks).
 2nd Digit (Main Dimensions) could indicate the proportion of the part's length to its
diameter, such as long, thin parts or short, thick parts.
 3rd Digit (Secondary Features) could represent specific features like holes, grooves, or
other surface features.
2) Supplementary Code
The supplementary code provides additional details that are important for
manufacturing and operational purposes, such as material type, tolerance, surface finish, or the
specific processes required to make the part (e.g., heat treatment, coating).
The supplementary code is less standardized than the basic code and can be adapted to fit
the specific needs of a company. It typically includes:
 Material: What material the part is made from (e.g., steel, aluminum).
 Tolerances: Information about the precision required for the part.

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  Surface Finish: Specific requirements for the surface treatment of the part (e.g.,
roughness or coating).
Example of Opitz Code Interpretation:
For the given part design shown define the "form code" using the Opitz system.

Step 1: The total length of the part is 1.75, overall diameter 1.25,
L/D = 1.4 (code 1)
Step 2: External shape - a rotational part that is stepped on both with one thread (code 5)
Step 3: Internal shape - a through hole (code 1)
Step 4: By examining the drawing of the part (code 0)
Step 5: No auxiliary holes and gear teeth (code 0)
Code: 15100

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 Benefits of the Opitz System
 Standardization: It provides a standardized way of classifying parts, making it easier to
manage inventories, manufacturing processes, and design activities.
 Reduced Setup Time: Grouping similar parts helps reduce machine setup times because
parts that require the same machining processes can be batched together.
 Improved Design Reuse: Engineers can identify existing parts that meet new design
requirements, reducing the need to create new designs from scratch.
 Optimized Production Planning: Manufacturers can optimize production schedules by
grouping parts that require similar manufacturing processes, improving efficiency.
Applications of the Opitz System
 Manufacturing: Classifying and coding parts for efficient production planning, tool
management, and reducing machine downtime.
 Inventory Control: Facilitating part identification for better inventory management,
procurement, and part reuse.
 Product Design: Supporting design engineers by helping them quickly identify and reuse
existing parts or standard components, reducing design time and cost.
 Supply Chain Management: Managing suppliers and vendors by using a common
classification system to ensure consistent part specification.
Limitations of the Opitz System
 Customization Required: The system needs to be tailored to specific industries or
companies, requiring some initial setup and fine-tuning.
 Complexity for Detailed Parts: For parts with complex geometries or numerous
attributes, the Opitz system can become cumbersome to apply.
 Technological Updates: may require updates to accommodate modern manufacturing
technologies like additive manufacturing (3D printing).

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 3. Explain production flow analysis (PFA).
Production flow analysis (PFA), developed by Burbridge in 1971, is a method for
identifying part families and associated machine groupings that uses the information contained
on production route sheets rather on part drawings.
In PFA, work parts with identical or similar routings are classified into part families. It
may be noted that PFA neither uses a classification and coding system nor part drawings to
identify families. Instead, it uses the information such as part number, operation sequence, lot
size, etc., contained on the route sheet.
Since this method is based on the route sheet information, it is sometimes referred as the
route sheet inspection method.
The steps involved in Production Flow Analysis (PFA)
1) Data collection
2) Soriation of process routings
3) PFA chart
4) Cluster analysis
1) Data Collection:
In the initial step of Production Flow Analysis, detailed data is collected about the
manufacturing process. This data forms the foundation for the rest of the analysis. Key
information gathered includes:
 Parts: List of parts produced, including their numbers, types, and attributes.
 Routing information: The sequence of operations each part follows through various
machines in the factory.
 Machines: Details about the machines used, including their capabilities and types of
operations they perform.
 Operation times: How long it takes to complete each operation on each machine.
 Material movement: The movement of parts between machines, including transportation
methods and distances.
This data will later be used to analyze and group parts based on their process routing.
2) Sortation of Process Routings:
Sortation (or sorting) refers to the organization of process routing data to identify
patterns and similarities between parts. During this step:
 The sequence of operations for each part is sorted to group parts with similar routing
paths through the machines.
 The goal is to find parts that share the same or similar manufacturing processes, which
can then be grouped into part families.
For example, parts that need similar processes, such as milling, turning, or drilling in the
same order, are identified as having similar routings. This is an essential step in creating an
optimized production flow.
3) PFA Chart
The PFA chart is a graphical representation of the process routings for each part and
their relationships to the machines. This chart helps identify commonalities between parts and
provides a clear picture of the production flow. To create the PFA chart:

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  The parts are listed along one axis, and the machines are listed along the other axis.
 Each entry in the chart indicates the specific machine each part uses in its production
process.
For example:

In this PFA chart:

 An "1" represents an operation performed by the respective machine for a particular part.
 By analyzing the chart, it becomes easier to spot similarities in part routings, which aids
in grouping similar parts together.
4) Cluster Analysis
Once the PFA chart is complete, cluster analysis is performed to identify natural groupings of
parts and machines. The aim is to:
 Group parts with similar process flows into part families.
 Group the corresponding machines that are used by these part families into
manufacturing cells.
Cluster analysis looks for overlapping patterns in the PFA chart. Parts that use the same
machines in similar sequences are clustered together, and these clusters suggest how machines
can be arranged into manufacturing cells.

Advantages:
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 a) Identification of bottlenecks: Helps to pinpoint areas that are slowing down
the production process.
b) Reduction of waste: Identifies and eliminates waste, such as waiting time, excess
inventory, and unnecessary movement.
c) Improved efficiency: Leads to more efficient use of resources and equipment.
d) Enhanced productivity: Increases overall output and reduces production time.
e) Better quality control: Helps to identify and address quality issues early in the process.
f) Cost reduction: Can lead to significant cost savings by reducing waste and improving
efficiency.
g) Improved customer satisfaction: By reducing lead times and improving quality,
customer satisfaction can be enhanced.
Disadvantages:
a) Time-consuming: Conducting a thorough production flow analysis can be time-
consuming, especially for complex processes.
b) Requires data: Accurate data is essential for effective analysis, which can
be challenging to obtain.
c) Resistance to change: Implementing changes based on the analysis may face resistance
from employees or management.
d) Limited to current processes: Production flow analysis is focused on the current state
and may not consider future changes or improvements.
e) May not address all issues: While it can identify and address many problems, it may
not be able to solve all issues in a manufacturing process.
4. Explain the benefits of group technology.
Group Technology (GT) brings numerous benefits to various aspects of manufacturing,
including product design, tooling and setups, materials handling, production and inventory
control, process planning, and management. Some specific benefits of Group Technology in
these areas:
1) Product Design
 Standardization of Designs: By classifying parts into families, GT encourages the reuse
of existing designs, reducing the need for creating new designs from scratch. This saves
time and resources in the design phase.
 Reduced Design Complexity: Grouping similar parts simplifies the design process,
making it easier to optimize and modify parts based on existing design templates, which
leads to quicker design iterations and reduced design errors.
 Improved Design Efficiency: Designers can work more efficiently by using standardized
features and components, leading to faster development cycles and more consistent
product designs.
2) Tooling and Setups
 Reduced Setup Times: By organizing parts into families with similar manufacturing
processes, GT reduces the frequency and complexity of machine setups. This allows
machines to handle multiple parts without significant changes in tooling.

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  Standardized Tooling: Similar parts use standardized tooling, reducing the need for
custom tools. This lowers tooling costs and shortens the time required for tool changes.
 Increased Equipment Utilization: Group Technology maximizes the use of specialized
machines and tools, allowing companies to produce more parts with fewer disruptions
and minimizing downtime.
3) Materials Handling
 Efficient Material Flow: GT helps organize the production layout by grouping similar
processes together, which minimizes unnecessary material movement and reduces
transportation distances within the plant.
 Simplified Material Handling Systems: The grouping of parts enables more efficient
material handling systems. Fewer material transfers are required between machines,
leading to faster production and fewer chances for errors or damage.
 Reduced Material Handling Costs: Less movement of materials between departments
or machines leads to reduced labor and handling costs, contributing to leaner operations.
4) Production and Inventory Control
 Simplified Production Scheduling: Grouping parts into families makes it easier to
schedule production, as similar parts can be processed together. This leads to better
workflow and fewer bottlenecks.
 Lower Work-in-Progress (WIP) Inventory: GT reduces the number of unfinished parts
in the production process, decreasing the need for large WIP inventories and minimizing
inventory holding costs.
 Faster Response to Customer Orders: With shorter lead times and more predictable
production flows, GT enables quicker responses to customer demands and faster
fulfillment of orders.
 More Accurate Forecasting: GT allows for better inventory control, as parts are
grouped into predictable families, improving demand forecasting and reducing stockouts
or excess inventory.
5) Process Planning
 Streamlined Process Design: GT simplifies process planning by allowing engineers to
develop processes for part families rather than individual parts, leading to standardized,
efficient workflows.
 Efficient Use of Resources: Group Technology enables process planners to assign
machines and operators to specific families of parts, optimizing resource allocation and
reducing the need for frequent adjustments in process planning.
 Faster Process Changes: When new parts are introduced, the process planning is
simplified because many of the required processes are already in place for similar parts.
This reduces the time required for new process development and validation.
6) Management and Employees
 Improved Workforce Specialization: GT allows employees to become specialized in
handling certain families of parts, which can lead to higher skill levels, better job
satisfaction, and fewer errors.

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  Enhanced Employee Efficiency: Workers experience less downtime between tasks, as
they focus on a specific family of parts that require similar processes. This improves their
efficiency and reduces training time.
 Better Communication and Coordination: Management benefits from clearer
communication channels, as GT simplifies the production process. Fewer handoffs and
less complexity in workflows enhance coordination between teams.
 Enhanced Decision-Making: With clear, organized production processes, management
has more visibility into operations, allowing for better decision-making regarding
capacity planning, resource allocation, and productivity improvements.
 Increased Job Satisfaction: Employees benefit from working in a more organized,
predictable, and less stressful environment.
5. Explain cellular manufacturing with Rank order clustering (ROC) algorithm.
Rank Order Clustering (ROC) is a technique used for clustering binary data,
particularly in the context of machine-part grouping problems in manufacturing systems or
cellular manufacturing. This algorithm helps in rearranging the rows (machines) and columns
(parts) of a machine-part incidence matrix in a way that maximizes the block diagonal structure,
making it easier to identify machine-part families.
Key Steps in the Rank Order Clustering Algorithm
1. Construct the binary matrix: Start with a binary matrix where rows represent machines,
and columns represent parts. If a machine can process a part, the corresponding entry in
the matrix is marked as '1'; otherwise, it's marked as '0'.
2. Compute row binary values: For each row, calculate a binary value by treating the
entries in that row as a binary number. For example, if a row contains the values [1,0,1],
it will be treated as [101]2=5
3. Sort rows in descending order: Sort the rows of the matrix in descending order based
on the calculated binary values.
4. Compute column binary values: Repeat the same procedure for columns. Treat each
column as a binary number and sort the columns in descending order based on their
binary values.
5. Iterate: Repeat the process of computing binary values and sorting rows and columns
alternately until no further improvement is possible (the rows and columns stop
changing).
6. Cluster formation: After a few iterations, the matrix tends to cluster similar rows and
columns together, forming groups or blocks of 1s in the matrix. These blocks represent
machine-part families.
Example of Rank Order Clustering
Let’s take an example of a 3x4 binary machine-part matrix, where:
 Rows represent machines (M1, M2, M3).
 Columns represent parts (P1, P2, P3, P4).

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 Initial Machine-Part Matrix:
Machine / Parts P1 P2 P3 P4
Machine / Parts P1 P2 P3 P4
M1 1 0 1 0
M2 0 1 0 1
M3 1 1 0 0
Step 1: Compute Binary Values for Rows
We treat each row as a binary number. For example, M1’s row [1,0,1,0] is 10102=10.
 M1: [1,0,1,0] ⇒10102 =10
 M2: [0,1,0,1] ⇒01012 =5
 M3: [1,1,0,0] ⇒11002 =12
Step 2: Sort Rows Based on Binary Values
After sorting based on the binary values, the order of rows becomes:
Machine / Parts P1 P2 P3 P4
M3 1 1 0 0
M1 1 0 1 0
M2 0 1 0 1
Step 3: Compute Binary Values for Columns
Next, we treat each column as a binary number by reading the column from top to bottom:
 P1: [1,1,0] ⇒1102 =6
 P2: [1,0,1] ⇒1012 =5
 P3: [0,1,0] ⇒0102 =2
 P4: [0,0,1] ⇒0012 =1
Step 4: Sort Columns Based on Binary Values
After sorting the columns in descending order, the matrix becomes:
Machine / Parts P1 P2 P3 P4
M3 1 1 0 0
M1 1 0 1 0
M2 0 1 0 1
No further changes occur after sorting, and the algorithm terminates.
Final Matrix (after rank order clustering):
Machine / Parts P1 P2 P3 P4
M3 1 1 0 0
M1 1 0 1 0
M2 0 1 0 1

Interpretation:
The rows and columns are now rearranged such that clusters of 1s are more visible. In this case:
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  Machine M3 works on parts P1 and P2.
 Machine M1 works on parts P1 and P3. Machine M2 works on parts P2 and P4.
This clustering helps in identifying which machines and parts can be grouped
together in manufacturing cells.

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