A u s t r a l i a n C o n f e r e n c e on Manufacturing Engineering 17-19 August 1977

Component Batch Manufacture by Group Technology, a New Production System

A. W. BOUNDY
Lecturer. Darling Downs Institute of Advanced Education, Toowoomba

S M AL U M F Y Group Technology i s p r e s e n t e d a s a s y s t e m which p r o v i d e s t h e component b a t c h m a n u f a c t u r i n g i n d u s t r y w i t h t:he means o f c o n t r o l l i n g p r o d u c t i o n by t h e u s e o f , a s h o r t , s e q u e n c e d , p r e - p l a n n e d p r o d u c t i o n c y c l e couple!d w i t h a r e - o r g a n i z a t i o n o f shop f l o o r machines and p r o c e s s e s . B e n e f t t s enumerated i n t h i s p a p e r a r e t h o s e which m a i n l y a c c r u e i n t h e a r e a s of p r o d u c t i o n p l a n n i n g and c o n t r o l ; a complete e n u n c i a t i o n o f ' b e n e f i t s h a s been p r e s e n t e d i n a n e a r l i e r p a p e r , Boundy (1977).
A method commonly u s e d f o r t h e i m p l e m e n t a t i o n o f Group Technology i s d e s c r i b e d i n some d e t a i l , a n d i t s

i n t e r a c t i o n w i t h t h e advanced t e c h n i q u e o f n u m e r i c a l c o n t r o l i s d e a l t w i t h . F i n a l l y , a b r i e f c a s e s t u d y o f a p r o p o s e d Group Technology s y s t e m f o r a medium s i z e d m a n u f a c t u r i n g f i r m i s outlined.

INTRODUCTION

M a n u f a c t u r i n g methods used t o p r o d u c e b a t c h e s o f components a n d one o f f j o b s h a s p r e d o m i n a t l y f a v o u r e d systems designed around the f u n c t i o n a l l a y o u t of machine t o o l s and p r o c e s s e s . The s e g r e g a t e d p l a c e ment o f machine t o o l t y p e s i n t h e F u n c t i o n a l s y s t e m n e c e s s i t a t e s numerous movements o f component b a t c h e s i n orcler t o c o m p l e t e t h e o v e r a l l o p e r a t i o n s e q u e n c e . A d e s i r e t o a c h i e v e c o n t r o l o v e r p r o d u c t i o n throughp u t ' t i . m e s a s w e l l a s a t t a i n a smooth and e f f i c i e n t m a t e r i a l f l o w s y s t e m h a v e been f a c t o r s which h a v e f r u s t r a t e d f i r m s s i n c e m a n u f a c t u r i n g f i r s t began.
A measure o f t h e s u c c e s s o r o t h e r w i s e o f a f i r m ' s m a n u f a c t u r i n g s y s t e m c a n b e gauged by a walk a r o u n d l o o k a t t h e volume o f work i n p r o g r e s s l y i n g i d l e between o p e r a t i o n s and a c l o s e r i n s p e c t i o n o f t h e accompanying b a t c h p r o g r e s s d a t a w i l l u n d o u b t e d l y reveal. t h a t shop f l o o r t i m e s a r e measured by months i n many c a s e s . A s i t u a t i o n l i k e t h i s , when weeks can l a p s e between s u c c e s s i v e o p e r a t i o n s , makes production c o n t r o l non-existent and d e l i v e r y d a t e s a m a t t e r of when t h e y o c c u r .

improved p r o d u c t i v i t y f i g u r e s on t h e p r o v i s i o n o f a more c h a l l e n g i n g , s a t i s f y i n g working e n v i r o n m e n t f o r employees. O v e r s e a s , t h e s e c t o r o f m a n u f a c t u r i n g i n d u s t r y which h a s . b e n e f i t t e d g r e a t l y , b o t h from a s o c i o l o g i c a l and t e c h n o l o g i c a l v i e w p o i n t i s compone n t b a t c h p r o d u c t i o n when m a n u f a c t u r e d by a Group Technology s y s t e m .

2 2.1

THE CONCEPT OF GROW TECHNOLOGY Definition

'Group Technology i s a s y s t e m of m a n u f a c t u r e i n which a f i r m ' s component mix i s d i v i d e d i n t o a number o f f a m i l i e s b a s e d on g e o m e t r i c a l s h a p e whic'h i s i n d i c a t i v e of c e r t a i n types of machining operati o n s . The machine t o o l and p r o c e s s assemblage i s subsequently arranged i n t o groups o r c e l l s designed t o m a n u f a c t u r e t h e above f a m i l i e s , s o t h a t e a c h family i s completely processed within the confines of a p a r t i c u l a r c e l l i n a continuous o p e r a t i o n sequence. '

2.2

Production Control

During t h i s c e n t u r y , o t h e r t e c h n o l o g i c a l improvements h a v e , c o u p l e d w i t h t h e a d v a n c e s a c h i e v e d by n u m e r i c a l l y c o n t r o l l e d and computer a i d e d machine t o o l s and p r o c e s s e s , been a b l e t o b o o s t p r o d u c t i o n f i g u r e s many t i m e s o v e r . These b e n e f i t s , b e c a u s e o f t h e i r u n i v e r s a l a p p l i c a t i o n have n o t g i v e n a n y one n a t i o n a s i g n i f i c a n t a d v a n t a g e f o r v e r y l o n g . Succ e s s i n m a n u f a c t u r i n g comes from a f i r m ' s a b i l i t y t o a c h i e v e b e t t e r p r o d u c t i v i t y f i g u r e s t h a n i t s comp e t i t o r s . Low c o s t l a b o u r c o u n t r i e s s u c h a s J a p a n , Hong Kong, I n d i a , Taiwan a n d China e n j o y a n e x t r e m e l y low h a n d i c a p i n t h e p r o d u c t i v i t y s t a k e s . A u s t r a l i - a n t e c h n o l o g y must d e v e l o p m a n u f a c t u r i n g systeros which a r e more c o m p a t i b l e w i t h o u r f r e e t h i n k i n g a n d i n d e p e n d e n t way o f l i f e . These c h a r a c t e r i s t i c s have r e a c t e d i n c r e a s i n g l y a g a i n s t t h e m a s t e r servant relationship of t h e present t r a d i t i o n a l s y s t e m . Semi-autonomous group working is a s y s t e m which p r o p o s e s a d e g r e e o f independence and respons i b i l i t y f o r d a i l y t a s k s , b u t i t s use i n A u s t r a l i a t o d a t e h a s been m a i n l y r e s t r i c t e d t o worker p a r t i c i p a t i o n i n management. Such a p p l i c a t i o n s b a s e t h e i r

The most s i g n i f i c a n t d i f f e r e n c e between t h e Group Technology and F u n c t i o n a l s y s t e m s i s t h e d e g r e e o f c o n t r o l o v e r p r o d u c t i o n which i s i n h e r e n t i n e a c h . A comparison o f t h e component f l o w s y s t e m s c o u p l e d w i t h a n a p p r e c i a t i o n o f t h e p r i n c i p l e s which govern t h e i r operation w i l l underline t h i s difference. F i g u r e 1 shows t h e two t y p e s o f l a y o u t w i t h a t y p i c a l component b a t c h r o u t e superimposed on e a c h . The sequence o f o p e r a t i o n s r e q u i r e d f o r t h e b a t c h i l l u s t r a t e d i s , l a t h e , m i l l , inspect, grind, gear c u t , d r i l l and i n s p e c t . In the functional layout t h i s means v i s i t i n g a s e p a r a t e s e c t i o n f o r e a c h o p e r a t i o n , a s t h e r o u t e i n d i c a t e s . The foreman i n c h a r g e o f e a c h s e c t i o n a l o t t i n g t h e b a t c h on a r r i v a l t o a p a r t i c u l a r machine a s i t becomes a v a i l a b l e . The o p e r a t i o n i s t h e n c a r r i e d o u t on i n d i v i d u a l compone n t s , which a r e r e t u r n e d t o t h e b a t c h b i n a n d remove d from t h e s e c t i o n on t o t h e n e x t where a . s i m i l a r p r o c e s s i s r e p e a t e d . Even though e a c h b a t c h may b e accompanied b y i n s t r u c t i o n s a s t o when i t i s due o u t o f a s e c t i o n and on t o t h e n e x t , t h e s e c o m p l e t i o n d a t e s a r e o f t e n u n a t t a i n a b l e a n d i n many c a s e s p a s t

which a r e most a p p e a l i n g t o t o d a y s p r o d u c t i o n engineer. F i r s t l y , continuous operations provide Secondly, t h e s h o r t e s t p o s s i b l e t h r o u g h p u t times. by minimizing i n t e r - o p e r a t i o n s t o r a g e , work i n prog r e s s i s k e p t t o an a b s o l u t e minimum. T h i r d l y , o r d e r s r e l e a s e d on t h e shop f l o o r d u r i n g a p a r t i c u l a r p r o d u c t i o n c y c l e a r e g u a r a n t e e d of d e l i v e r y by t h e end of t h e c y c l e , t h e r e f o r e , .components can be planned f o r manufacture much c l o s e r , t o t h e i r assembl y d a t e , t h u s r e d u c i n g t h e amount of s t o c k s necessa r y t o e n s u r e an u n i n t e r r u p t e d assembly programme. The above f a c t o r s c o n t r i b u t e a f a r g r e a t e r measure of c o n t r o l t o p r o d u c t i o n e n g i n e e r i n g t h a n i s possi b l e w i t h i n a F u n c t i o n a l system. 3 3.1 IMPLEMENTATION OF GROUP TECHNOLOGY Component Family Formation

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FUNCTIONAL COMPONENT BATCH ROUTE

A s s t a t e d i n t h e above d e f i n i t i o n , t h e f i r s t t a s k of a Group Technology implementation i s t o d i v i d e t h e component mix i n t o g e o m e t r i c a l l y s i m i l a r famili e s . T h i s a s p e c t of t h e e x e r c i s e i s most i m p o r t a n t a s t h e f i n a l grouping of machine t o o l s and p r o c e s s e s depends on t h e f a m i l i e s which emerge from t h e component mix. A method which i s r e a d i l y a v a i l a b l e and c o n s i d e r e d by many t o b e t h e most e f f e c t i v e , i s t h a t of component c l a s s i f i c a t i o n and coding.
3 . 1 . 1 C l a s s i f i c a t i o n and Coding

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The approach t o component f a m i l y formation by c l a s s i f i c a t i o n and coding, r e q u i r e s a t o t a l a p p r a i s a l of a f i r m ' s drawing f i l e i n o r d e r t o a l l o c a t e a code Two numerical c l a s s i f number t o e v e r y component. i c a t i o n systems i n widespread u s e a r e : ROUTE (i) t h e B r i s c h system, Gombinski ( 1 9 6 9 ) , which i s d e s i g n - o r i e n t a t e d i . e . components a r e grouped i n t o f a m i l i e s by t h e s i m i l a r i t y of d e s i g n m a n i f e s t i n t h e i r o v e r a l l shape. ( i i ) t h e Opitz system, O p i t z (1970), which i s prod u c t i o n - o r i e n t a t e d i . e . components a r e grouped i n t o families requiring closely similar o r identical technological processes. ' N e i t h e r of t h e s e two systems were designed e x p r e s s l y f o r Group Technology; t h e B r i s c h system h a s t o be e x t e n s i v e l y modified f o r t h e purpose w h i l s t t h e Opitz system, b e i n g a p r o d u c t i o n o r i e n t a t e d system, r e q u i r e s minor a l t e r a t i o n s t o s u i t t h e unique r e quirements of t h e f i r m concerned. The B r i s c h system requires specialised consultation f o r i t s i n s t a l l a t i o n and proves r a t h e r c o s t l y . There i s l i t t l e doubt t h a t i f a f i r m i s p r e p a r e d t o make a s u b s t a n t i a l investment i n a B r i s c h c l a s s i f i c a t i o n system, i t would.pave t h e way t o a s a t i s f a c t o r y implementation of Group' Technology. Such s u c c e s s f u l examples a s F e r a n t i Ltd. , Durie (1969), and Serck Audco, Ranson (1972), speak w e l l f o r t h e B r i s c h system when properly applied. The advantage of t h e O p i t z o v e r t h e B r i s c h code i s t h a t i t i s r e a d i l y a v a i l a b l e a t no r e a l c o s t t o a f i r m , a l t h o u g h m o d i f i c a t i o n s a r e n e c e s s a r y t o one o r b o t h p a r t s of t h e code. Once t h i s i s done, coding can b e c a r r i e d o u t by a f i r m ' s own p e r s o n n e l . The Opitz code i s a two p a r t code, t h e f i r s t p a r t p r o v i d i n g a g e o m e t r i c a l d e s c r i p t i o n of t h e component and t h e second p a r t g i v e s , d i m e n s i o n a l , m a t e r i a l , and g e n e r a l manufacturing i n f o r m a t i o n . The code h a s independent d i g i t a l s i g n i f i c a n c e , s o t h a t e x t r a d i g i t s may b e added t o p r o v i d e more i n f o r m a t i o n v i t h o u t a f f e c t i n g p r e v i o u s d i g i t s . F i g u r e 2 shows a modified v e r s i o n of t h e O p i t z code i n s t r u c t u r e

CELLULAR COMPONENT BATCH Figure 1

Comparison Between F u n c t i o n a l and C e l l u l a r Layouts.

b e f o r e t h e b a t c h even a r r i v e s a t t h e s e c t i o n i n q u e s t i o n . Hence due d a t e s on o r d e r s l o s e t h e i r s i g n i f i c a n c e and p r o g r e s s c h a s i n g becomes n e c e s s a r y t o r e - e s t a b l i s h p r i o r i t i e s . Many b a t c h e s en r o u t e through t h e system l a g f u r t h e r and f u r t h e r behind and t h e s t a t e of a f f a i r s on t h e shop f l o o r d e t e o r i a t e s t o t h e e x t e n t where a l l a v a i l a b l e space i s s t a c k e d w i t h b a t c h e s of work i n p r o g r e s s .

O t h e o t h e r hand t h e c e l l u l a r system does n o t have n the inherent layout d e f i c i e n c i e s experienced with t h e f u n c t i o n a l l a y o u t . Each c e l l u l a r group h a s w i t h i n i t s s m a l l b o u n d a r i e s t h e machines n e c e s s a r y t o manufacture t h e f a m i l y of components f o r which i t h a s been s p e c i f i c a l l y designed. The l a y o u t i s such t h a t work flow i s predominatly through key machines f o r f i r s t o p e r a t i o n s and f i n a l l y through s u p p o r t machines f o r a u x i l i a r y o p e r a t i o n s . This arrangement a l o n e s h o r t e n s component r o u t e s by a f a c t o r of many t i m e s and i n a d d i t i o n e s t a b l i s h e s s o l e r e s p o n s i b i l i t y f o r manufacture. Another imp o r t a n t f e a t u r e of c e l l u l a r manufacture i s t h a t comp o n e n t s undergo a c o n t i n u o u s o p e r a t i o n sequence s o t h a t t h e y a r e p r e f e r a b l y n o t b i n f e d between machine t y p e s . T h i s philosophy develops t o a much h i g h e r degree of p e r f e c t i o n a s o p e r a t i v e s w i t h i n a c e l l g a i n e x p e r t i s e i n t h e l o a d i n g and sequencing a s p e c t s o f t h e i r c y c l i c p l a n n i n g t a s k . Also, i n t r a c e l l s t o r a g e and t r a n s p o r t f a c i l i t i e s such a s conveyors o r mobile p a l l e t s a l l o w f o r i n b a l a n c e between successive operations.
The c o n t i n u o u s o p e r a t i o n sequence of p r o c e s s i n g components i n a batch has t h r e e very important f e a t u r e s

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Modified O p i t z c l a s s i f i c a t i o n System.

form, which h a s been developed f o r a Group Technology i n v e s t i g a t i o n , Boundy (1975). Once a component h a s been c l a s s i f i e d i n t o one o f t h e classes shown under t h e f i r s t d i g i t , t h e remaini n g d i g i t s of t h e g e o m e t r i c a l code a r e s e l e c t e d from a s e p a r a t e c h a r t (one f o r e a c h c l a s s ) , s p e c i a l l y s e t o u t t o i n d i c a t e t h e g e o m e t r i c a l shape c h a r a c t e r i s t i c s i n t e c h n o l o g i c a l o r d e r o f p r o d u c t i o n . For example, p l a i n r o t a t i o n a l components have t h e i r e x t e r n a l shape d e s c r i b e d f i r s t , f o l l o w e d by i n t e r n a l s h a p e , t h e n p l a n e s u r f a c e f e a t u r e s (keyways, f l a t s , hexagons e t c . ) and l a s t l y t h e t y p e and p a t t e r n s o f a u x i l - i a r y h o l e s . Another p r o v i s i o n o f t h e code i s t h a t w i t h i n each d i g i t c l a s s shown i n F i g u r e 2, t h e o r d e r of complexity o f f e a t u r e s i n c r e a s e s from nothi n g t:o a maximum f o r c a t e g o r y 9. F i g u r e 3 i l l u s t r a t e s f e a t u r e s f o r t h e second and t h i r d d i g i t s o f t h e p l a i n r o t a t i o n a l f a m i l y o f components. By s t u d y i n g t h e f e a t u r e s of t h e second d i g i t ( e x t e r n a l shape e l e m e n t s ) , one can s e e t h a t t h e s e e l e m e n t s a r e a l l produced on a l a t h e . The f i r s t c a t e g o r y (0) i n d i c a t : e s no e x t e r n a l machining, whereas t h e n e x t t h r e e (1, 2 and 3 ) d e s c r i b e e l e m e n t s which can be p r o d ~ ~ c ew i t h o u t t h e need t o r e v e r s e t h e component d i n t h e l a t h e chuck. C a t e g o r i e s 4 , 5 and 6 i n which t h e component i s s t e p p e d t o b o t h e n d s r e q u i r e s r e v e r s a l i n t h e l a t h e o r a second set-up on a n o t h e r machi.ne. C a t e g o r i e s 7 , 8 and 9 a r e complex o p e r a t ions requiring s p e c i a l set-ups and/or t h e applicati o n of more s k i l l e d t e c h n i q u e s . The t h i r d d i g i t ( i n t e r n a l shape e l e m e n t s ) i s s t r u c t u r e d s i m i l a r l y t o d i g i t 2, but describes i n t e r n a l boring features.

3 . 1 . 2 The Computer P r i n t - o u t
P a r t o f t h e coding e x e r c i s e c o n s i s t s of e n t e r i n g a l l component i n f o r m a t i o n on t o c o d i n g d a t a s h e e t s which a r e c a r e f u l l y designed t o take advantage of t h e p r i n t - o u t c a p a b i l i t y o f t h e computer. Punched c a r d s a r e produced, one f o r e a c h component and a p r i n t - o u t o b t a i n e d i n a s c e n d i n g n u m e r i c a l o r d e r o f t h e geometri c a l code. Components a r e a u t o m a t i c a l l y s o r t e d i n t o families according t o the f i r s t d i g i t - t h e c l a s s d i g i t , F i g u r e 2. F i g u r e 4 shows a s m a l l s e c t i o n o f a p r i n t - o u t on which can be s e e n t h e t y p e o f i n f o r m a t i o n r e q u i r e d f o r machine g r o u p i n g a n a l y s i s . I t r e p r e s e n t s seven components, showing t h e end o f c l a s s (0) and t h e b e g i n n i n g o f c l a s s ( l ) . r o t a t i o n a l

Figure 3

Geometrical D i g i t s 2 and 3 of the P l a i n Rotational Class.

components. Machining d a t a c o n s i s t s o f t h e t o t a l number and sequence o f o p e r a t i o n s , machines, o p e r a t i o n and s e t - u p t i m e s . P a r t numbers, b a t c h s i z e s and a n n u a l q u a n t i t i e s a r e i n c l u d e d a s w e l l .

3.2

Formation o f Machine Groups

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5

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9 22 18 9 6 10 9 24 15 9 1 8 35 9 3 5 . 6 12 25 9 10 20

. . . . . .

9 9 9 9 9

16 15 12 14 3

10 76 4 0 20 10 93 30 15 10 76 4 0 0 .

. . . .

. . .

73

. .

79 20 25

73

Figure 4

S e c t i o n of Component P r i n t - o u t . normally used mid-cycle, some p r e l i m i n a r y o p e r a t i o n s a r e usually necessary t o provide l o c a t i n g o r reference surfaces, whilst f i n a l operations involving p l a n e s u r f a c e s (keyways, f l a t s e t c . ) may b e c a r r i e d o u t on s u p p o r t machines. Such r e q u i r e m e n t s a r e i d e a l f o r a c e l l u l a r s i t u a t i o n w i t h t h e machining c e n t r e f i l l i n g t h e r o l e of key machine and pacemaker. 5

Once t h e computer p r i n t - o u t i s o b t a i n e d , t h e a n a l y sis l e a d i n g t o t h e f o r m a t i o n of machine groups can begin. Such a n a l y s i s i s l a r g e l y manual, and many v a r i a t i o n s o f t h e p r i n t - o u t can be o b t a i n e d t o s i m p l i f y t h e t a s k . For example, a s o p e r a t i o n two i s p r o b a b l y c a r r i e d o u t on a key machine ( o p e r a t i o n one b e i n g e i t h e r saw-off ( 4 0 ) , o r o x y c u t ) , a p r i n t o u t may b e o b t a i n e d l i s t i n g a l l components r e q u i r i n g a c e r t a i n second o p e r a t i o n machine and from t h i s a l o a d i n g a n a l y s i s of t h a t machine i s r e a d i l y available. I n F i g u r e 4, t h e second o p e r a t i o n machi n e (No 9) i s a c a p s t a n l a t h e and a simple programme w i l l p r i n t o u t a l l components r e q u i r i n g t h i s machine. The e n s u i n g a n a l y s i s w i l l r e v e a l t h e number of t h e s e machines r e q u i r e d . There a r e no doubt many s a t i s f a c t o r y l a y o u t s which can be proposed, b u t t h e s k i l l o f t h e a n a l y s t w i l l u l t i m a t e l y d e c i d e how c l o s e t o t h e optimum w i l l be t h e f i n a l layout. 4 NUMERICAL CONTROL A D G O P TECHNOLOGY N RU

A PROPOSED GROUP TECHNOLOGY SYSTEM

Any proposed Group Technology system s h o u l d b e des i g n e d around t h e f o l l o w i n g f o u r p r i n c i p l e s : (i) (ii) (iii) (iv) a group l a y o u t of machines. a s h o r t , r i g i d , r o l l i n g production cycle. a planned l o a d i n g sequence. a s i n g l e c y c l e flow c o n t r o l of component stock ordering.

Raw Materials Most f a c t o r i e s and workshops of any s i z e today, a r e equipped w i t h n u m e r i c a l l y c o n t r o l l e d machine t o o l s . Because of t h e o u t s t a n d i n g advances made i n d e s i g n of NC machining c e n t r e s and l a t h e s d u r i n g t h e l a s t t e n y e a r s , a b r i e f look a t t h e c o m p a t i b i l i t y of t h e s e machines w i t h a G c e l l follows.' T MATER l AL NC l a t h e s a r e u s u a l l y f i r s t o p e r a t i o n machines and u n l e s s such machines a s key s e a t e r s , d r i l l s and m i l l s a r e readily available f o r a u x i l i a r y operati o n s , NC l a t h e s g e n e r a t e a f a r g r e a t e r volume of work i n p r o g r e s s t h a n e x i s t e d b e f o r e t h e i r u s e . For t h i s r e a s o n a n N C l a t h e i s an i d e a l pacemaker f o r a G t u r n i n g c e l l where s u p p o r t machines a r e T of s u i t a b l e t y p e and number t o e n s u r e a c o n t i n u o u s flow o f components SU PPLY PRODUCTION

Finished Products

CELLS PRODUCT

PRODUCT

,ASSEMBLY CELLS

ASSEMBLY L l NE

CELLS TRANSPO

I
Figure 5 5.1
A Case Study

COMPONENT

STORES Items

It h a s been s t a t e d , Craven (1973), t h a t i n c e l l u l a r manufacture t h e d e s i r e t o r e d u c e b a t c h s i z e s i n e v i t a b l y l e a d s t o an i n c r e a s e i n set-up t i m e s , e s p e c i a l l y on c o n v e n t i o n a l l a t h e s which r e q u i r e t o o l changes and numerous s t o p s e t t i n g s . Such an e f f e c t may be avoided by i n s t a l l i n g an NC l a t h e which h a s an e x t r e m e l y low set-up time. T h i s f e a t u r e a l l o w s s m a l l e r b a t c h e s t o be manufactured e c onomically w i t h o u t i n c r e a s i n g t h e volume of work i n progress.
Machining c e n t r e s have t h e c a p a b i l i t y of f u l f i l l i n g t h e r o l e of a number of d i f f e r e n t t y p e s of convent i o n a l machines. They a r e p a r t i c u l a r l y u s e f u l f o r machining a s i n g l e complex component, t h e number of operations possible being r e s t r i c t e d b y ' t h e l i m i t a t i o n s of s i z e of t h e i r t o o l magazine. I t i s claimed, Craven (1973) t h a t t h i s inadequacy i s l e s s e n e d i n a G c e l l where t o o l v a r i e t y f o r a chosen component T f a m i l y i s l i m i t e d , t h u s widening t h e machining c e n t r e ' s p r o c e s s i n g c a p a b i l i t y t o i n c l u d e a subf a m i l y of components. A s t h e machining c e n t r e i s

*Vendor

Proposed Group Technology C e l l System

F i g u r e 5 i s a proposed f u l l y i n t e g r a t e d p r o d u c t i o n system f o r a f a c t o r y employing some 700 workers m a n u f a c t u r i n g equipment f o r t h e s u g a r h a r v e s t i n g i n d u s t r y . The company h a s a l a r g e c o n v e n t i o n a l machine-shop t o g e t h e r w i t h a n e x t e n s i v e f a b r i c a t i o n s e c t i o n , because a l a r g e number of components a r e oxy-cut and welded t o form sub-assemblies. Vendor i t e m s a r e bought i n t o supplement in-house compone n t s i n sub-assembly and f i n a l assembly l i n e . Raw m a t e r i a l s t o c k s a r e h i g h and vendor i t e m s . a c c o u n t f o r a s u b s t a n t i a l percentage of the f i n a l product. The company developed from v e r y s m a l l b e g i n n i n g s and h a s expanded t o i t s p r e s e n t s i z e d r a m a t i c a l l y o v e r t h e l a s t f i v e y e a r s due t o an e v e r i n c r e a s i n g home and e x p o r t market. P r o d u c t i o n f a c i l i t i e s based

on a f u n c t i o n a l l a y o u t a r e p r e s e n t i n g t h e company w i t h d e l i v e r y d a t e problems, e x c e s s i v e work i n prog r e s s , a l a r g e volume of f i n i s h e d s t o c k s and prod u c t i o n p l a n n i n g and c o n t r o l d i f f i c u l t i e s which seem insurmountable. Following a t t e n d a n c e a t a seminar on t h e p r i n c i p l e s of Group Technology, t h e f i r m ' s t o p e n g i n e e r s recommended t h a t a f e a s i b i l i t y s t u d y s h o u l d b e undertaken t o a s s e s s whether o r n o t t h e new system could be s u i t a b l y a p p l i e d t o t h e f i r m ' s range of products.
A t h r e e months s t u d y followed, c u l m i n a t i n g i n t h e p r e s e n t a t i o n of a r e p o r t which proposed t h a t Group Technology had much t o o f f e r t h e f i r m and i t s emp l o y e e s . A c l o s e r look a t F i g u r e 5 w i l l show t h a t t h e m a t e r i a l flow system i s h i g h l y i n t e g r a t e d , from t h e raw m a t e r i a l s t a g e through t o f i n a l a s s embly. A complete c e l l u l a r system i s e n v i s a g e d , involving four d i f f e r e n t c e l l types i n a d d i t i o n t o t h e p r o d u c t assembly which i s n o t planned f o r group assembly a t t h i s s t a g e .

w i l l b e reduced by a s much a s 30%.

6 CONCLUSIONS

The Group Technology system, because of i t s s h o r t d e f i n e d and sequenced p r o d u c t i o n c y c l e , i n h e r e n t l y provides a r i g i d c o n t r o l over production. A c l a s s i f i c a t i o n system p r o v i d e s an e f f e c t i v e method of forming component f a m i l i e s and e n a b l e s t h e d e s i g n department t o e s t a b l i s h a d e s i g n r e t r i e v a l f a c i l i t y t o g e t h e r w i t h a bank of component s t a n d a r d i s a t i o n d a t a , Boundy (1975). Q u a l i t y C o n t r o l i s e f f e c t i v e l y accomplished w i t h i n individual c e l l s a s successive operatives moniter t h e performance of t h e p r e c e d i n g o p e r a t i v e and w i t h continuous operations r e c t i f i c a t i o n i s enforced almost immediately. A Group Technology m a t e r i a l flow system i s a s e r i e s of pre-planned, r e p e t i t i v e and w e l l o r d e r e d r o u t e s which e n a b l e an e f f i c i e n t and r e l i a b l e i n t e r n a l t r a n s p o r t system t o be developed. A w e l l designed computer p r i n t o u t can g r e a t l y f a c i l i t a t e t h e a n a l y s i s of component f a m i l i e s w i t h r e s p e c t t o machine a l l o c a t i o n s and l o a d i n g s . When used i n a c e l l u l a r s i t u a t i o n , n u m e r i c a l l y cont r o l l e d machine t o o l s , because o f t h e i r e x t r e m e l y low s e t t i n g t i m e s o f f s e t t h e tendency t o i n c r e a s e s e t t i n g times a s is t h e case with conventional machines, when s m a l l e r b a t c h e s a r e proposed. A c e l l system i s unique f o r a p a r t i c u l a r f i r m , b e i n g designed t o c a p t u r e a l l components p r e s e n t l y manufactured by t h e machine assemblage which c u r r e n t l y e x i s t s on the. shop f l o o r . Group Technology i s a t o t a l l y i n t e g r a t e d system of manufacture, i n c o r p o r a t i n g a l l a c t i v i t i e s on t h e shop f l o o r , from raw m a t e r i a l s i n p u t t o f i n a l assembly.

Commencing a t t h e i n p u t of raw m a t e r i a l s , i s a unique c e l l whose c o n t r a c t i t i s , v i a i n f o r m a t i o n from pl.anning and c o n t r o l , t o p r e p a r e and d e l i v e r raw m a t e r i a l s t o t h e f a b r i c a t i o n .and p r o d u c t i o n c e l l s p r i o r t o t h e s t a r t of t h e r e l e v a n t p r o d u c t i o n c y c l e , and t o t r a n s p o r t f i n i s h e d b a t c h e s and subassemblies t o t h e i r next d e s t i n a t i o n . F a b r i c a t i o n c e l l s a r e p r i m a r i l y concerned w i t h t h e p r o d u c t i o n of f a b r i c a t e d components f o r sub-assembly c e l l s a.nd t h e f i n a l assembly l i n e , a s w e l l a s prov i d i n g c u t p l a t e , b l a n k s e t c . f o r machining i n t h e production c e l l s . Fabrication c e l l s a r e not ins t a l l e d , w i t h h i g h c a p i t a l c o s t machines and hence t h e i r o u t p u t can be v a r i e d from time t o time, t h a t i s , t h e y have a r e a s o n a b l y f l e x i b l e s t r u c t u r e . P r o d u c t i o n c e l l s on t h e o t h e r hand, once designed and p o s i t i o n e d , a r e s t r u c t u r e d much more r . i g i d l y t o manufacture a c e r t a i n f a m i l y of components, hence t h e r e would be no d e s i r e t o a l t e r t h i s unique c a p a c i t y . Perhaps t h e replacement of c o n v e n t i o n a l w i t h NC machines o r some minor changes might be contemplated t o improve e f f i c i e n c y , b u t c e r t a i n l y no r a d i c a l change would o c c u r . P r o d u c t i o n c e l l s designed t o produce components of a c e r t a i n geom e t r i c a l shape w i l l c o n t i n u e t o do s o i n t h e f o r s e e a b l e f u t u r e , even though t h e f i r m ' s p r o d u c t s may undergo numerous changes i n d e s i g n and c o n s t r u c t i o n . Product sub-assembly c e l l s c o n s i s t mainly of s p e c i a l f i x t u r e s t o a i d i n assembly t o g e t h e r w i t h w e l d e r s , d r i l l s and numerous hand o p e r a t e d t o o l s r e q u i r e d f o r t h i s t y p e of work. These c e l l s a r e h i g h l y f l e x i b l e and change c o n s t a n t l y a s new models a r e i n t r o duced r e q u i r i n g d i f f e r e n t sub-assemblies. The system i s i n h e r e n t l y s e l f - c o n t r o l l i n g i n r e s p e c t t o p r o d u c t i o n . Each c e l l works t o a s h o r t d e f i n e d p r o d u c t i o n c y c l e which i s planned i n advance. Work c a r r i e d o u t i n each c e l l i s complete, t h e fragmenta t i o n of o p e r a t i o n s no l o n g e r e x i s t s , and r e s p o n s i b i l i t i e s a r e c l e a r l y d e f i n e d . Shop f l o o r p l a n n i n g and c o n t r o l f o r t h e t o t a l manufacture of i n d i v i d u a l c e l l p r o d u c t s i s c a r r i e d o u t by t h e o p e r a t i v e s of the particular cells.
It i s c o n f i d e n t l y e x p e c t e d w i t h t h e implementation of t h i s system, t h a t t h e f i r m ' s component throughp u t t i m e s w i l l be c o n t r o l l e d and s h o r t e n e d and t h e i r p r e s e n t l y l a r g e s t o c k of work i n p r o g r e s s

REFERENCES

BOUNDY, A. W. (1977), Group Technology, an Emerging New System f o r Batch Manufacture, I.E. Abst. Management Conference, Uni. o f Newcastle, May 1977.

COMBINSKI, J. (1969), The B r i s c h C l a s s i f i c a t i o n and Group Technology, P r o c e e d i n g s of I n t e r n a t i o n a l Seminar, S e p t . 1969, T u r i n , I t a l y . OPITZ, H. (1970), A C l a s s i f i c a t i o n System t o Desc r i b e Workpieces, P a r t s 1 and 2, Pergamon P r e s s , Oxford, 1970. DURIE, F.R.E. (1969), Group Technology a s Applied in a n E l e c t r o n i c Firm, P r o c e e d i n g s of I n t e r n a t i o n a l Seminar, S e p t . 1969, T u r i n , I t a l y .
RANSON, G.M. McGraw-Hill,

(1972), Group Technology, Pub. by 1972.

BOUNDY, A.W. (1975), An Approach t o Group Technology by C l a s s i f i c a t i o n and Coding, M. P h i l . T h e s i s , Uni. of Aston i n Birmingham, 1975.

CRAVEN, F.W. (1973), The Use of NC i n Group Technology, T h i r d Annual G Conference, S h e f f i e l d , T I . Prod. E . , Nov. 1973.