Group Technology and Cellular Manufacturing: Anan Mungwattana

Group Technology and
Cellular Manufacturing
Anan Mungwattana
Introduction
Throughput time/lead time is the total time
required to manufacture an item.
Order preparation time

Queue time
Set-up time
Processing time
Transportation time
Inspection time and put away time
Anan Mungwattana
Group Technology and Cellular

Manufacturing
Introduction
5% time on machine
How 5% is spent
14% - set-up time

17% - load/unload parts
17% - tool change
16% - inspection time
36% - actual cutting (adding value)
Anan Mungwattana

Manufacturing
Introduction
Challenges in new manufacturing requirements
Reduced product life cycles

More choices of products
On time delivery
High quality products
Mfg systems must have a product range which

meets market demand in terms of variety,
delivery, quality and cost.
Anan Mungwattana

Manufacturing
Introduction
Volume
High
Product
Planning
Department
Product
Layout
Medium
Fixed Location
Layout
Fixed Materials
Location
Planning
Department
Product
Family
Planning
Department
Group Technology
Layout
Process
Layout
Process
Planning
Department
Low
Low
Anan Mungwattana
Medium
Manufacturing
High
Variety
5
Fixed-Position Manufacturing
System
Lathe
Press
Grind
W
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e
S
t
o
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e
Weld
Anan Mungwattana
Paint
Assembly

Manufacturing
Job Shop Manufacturing System
Lathe
S
t
o
r
a
g
e
Lathe
Drill
Weld
Lathe
Lathe
Drill
Paint
Mill
Mill
Grind
Assembly
Mill
Mill
Grind
Assembly
Anan Mungwattana

Manufacturing
Weld
Paint
W
a
r
e
h
o
u
s
e
Flow Shop Manufacturing System/

Product Layout
Lathe
S
t
o
r
a
g
e
Drill
Press
Bend
Mill
Drill
Lathe
Lathe
Anan Mungwattana
Grind
Drill
Drill
A
s
s
e
m
b
l
y
W
a
r
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h
o
u
s
e
Drill

Manufacturing
Cellular Manufacturing System/

Group Technology
Lathe
S
t
o
r
a
g
e
Drill
Grind
Assembly
Mill
Assembly
Weld
Paint
Press
Lathe
Drill
Press
Assembly
Grind
Drill
Assembly
Drill
Grind
Anan Mungwattana

Manufacturing
W
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Introduction
Batch manufacturing
The most common form of production.
The most difficult to over come for low-cost
products.
About 75% of all machined components are
produced in batches of 50 or fewer.
The cost to build a product in small batches can
be 10 to 100 times higher that its mass
production cost.
Anan Mungwattana

Manufacturing
10
Introduction
Job shop layout for batch manufacturing
Majority of factories today are arranged as
functional layouts with a grouping of common
process equipment.
Products must flow from department to
department through manufacturing process.
Difficulty in production scheduling and control
as well as excessively long queue time.
Anan Mungwattana

Manufacturing
11
Introduction
Lathing
Milling
Drilling
M
Grinding
Receiving and
shipping
Anan Mungwattana
Assembly
A

Manufacturing
G
12
Introduction
End results:
higher inventory cost,
more overhead personnel to handle the
production control tasks, and
less customer satisfaction cause excessively
long delivery time.
Anan Mungwattana

Manufacturing
13
Production System/Efficiency
Part
Operation Sequence / Time
Demand
M1 (2) M2 (3) M3 (1)
100
Anan Mungwattana

Manufacturing
14
Production System/Efficiency
Max Time =
Min Time =
Why?
Anan Mungwattana

Manufacturing
15
Group Technology
Realization that many problems are similar, and
that by grouping similar problems, a single
solution can be found to a set of problems, thus
saving time and effort.
Method of technological process development,
equipment planning and efficient setting of the
machine tool, so as to insure the most profitable
technical planning of production in the shortest
time.
Anan Mungwattana

Manufacturing
16
Group Technology
GT is a mfg philosophy identifying similar
parts and grouping them together into
families to take advantage of their
similarities in design and mfg.
A part family is a collection of parts which are
similar either because of geometric shape and
size or similar processing steps required in their
manufacture
Anan Mungwattana

Manufacturing
17
Group Technology
Identifying the part families.
Visual inspection
Part classification and coding
Production flow analysis
Rearranging production machines into machine

cells.
A mfg. cell consists of several functionally
dissimilar machines which are placed in close
proximity to one another and dedicated to the
manufacture of a part family.
Anan Mungwattana

Manufacturing
18
Group Technology
L
Assembly
area
A
Cell 2
Cell 1
Receiving
Cell 3
L
Anan Mungwattana

Manufacturing
Shipping
19
Visual Inspection
Visual Inspection Method arrange a set of
part into groups known as part family by
visually inspecting the physical
characteristics of the parts.
Anan Mungwattana

Manufacturing
20
Visual Inspection
Anan Mungwattana

Manufacturing
21
Visual Inspection
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/yr, tolerance = 0.001 inch, 188 stainless steel
Anan Mungwattana

Manufacturing
22
Visual Inspection
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 milling
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Manufacturing
23
Part Classification and Coding

Similarities among parts are identified, and
these similarities are related in a coding
system.
Part similarities can be distinguished:
Design attributes include configuration,
material types, dimensional envelope, etc.
Mfg features include operations and their
sequences, machine tools to perform
operations, processing times, etc.
Anan Mungwattana

Manufacturing
24

Reasons for using coding scheme:
Design retrieval: A simple change in an existing
part take less time than designing a new part from
scratch.
Automated process planning: Part code for a new
part can be used to search for process plans for
existing parts with identical or similar codes.
Machine cell design: Part codes can be used to
design machine cells capable of producing all
members of a particular part family.
Anan Mungwattana

Manufacturing
25

Coding is a process of establishing symbols to
be used for meaningful communication.
Classification is a separation process in which
items are separated into groups based on the
existence or absence of characteristic attributes.
Coding can be used for classification purpose.
Classification requirements must be considered
during the construction of coding scheme.
Anan Mungwattana

Manufacturing
26

Before a coding scheme can be constructed,
a survey of all component features must be
completed and then code values can be
assigned to the features.
Selection of relevant features depends on
the application of the coding scheme.
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Manufacturing
27

Tolerance may not be important for design
retrieval; therefore, it is not a feature in a
design-oriented coding system.
In a mfg-oriented coding system, tolerance
is indeed an important feature.
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Manufacturing
28

System based on part design attributes
System based on manufacturing attributes
System based on both design and
manufacturing attributes
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Manufacturing
29

Design Attributes
Basic external shape
Basic internal shape
Rotational shape or
rectangular shape
Material types
Part function
Anan Mungwattana
Mfg Attributes
Processes
Operation sequence
Machine
Cycle time
Batch size
Cutting tools

Manufacturing
30
Structures in Classification
and Coding Schemes
Hierarchical structure (monocode): the
interpretation of each successive symbols
depends of the value of the preceding symbols.
Chain type structure (polycode): the
interpretation of each symbol in the sequence
is always the same.
Mixed mode structure: hybrid of the two
previous codes.
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Manufacturing
31
Opitz Classification System

A GT code is a string of characters capturing
information about an item.
The number of digits in the code can be ranged
from 6 to 30.
The most used system used is Opitz classification
system.
Opitz considers both design and manufacturing
information.
It is intended for machined parts.
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Manufacturing
32

Opitz coding scheme
12345
Form Code
6789
ABCD
Supplementary
Secondary
code
code
The first nine digits are intended to convey

both design and manufacturing data.
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Manufacturing
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Anan Mungwattana

Manufacturing
34

The first five digits are called form code
describing primary design attributes of part:
Digit 1: Part class

Digit 2: External shape
Digit 3: Internal shape
Digit 4: Plane surface machining
Digit 5: Auxiliary holes and gear teeth
Anan Mungwattana

Manufacturing
35

The next four digits constitute the
supplementary code:
Digit 6: Dimension
Digit 7: Material
Digit 8: Original of raw materials
Digit 9: Accuracy
Anan Mungwattana

Manufacturing
36

The extra four digits are referred to as
secondary code and are intended to identify
the production operation type and sequence.
The secondary code can be designed by the
user firm to serve its own particular needs.
Anan Mungwattana

Manufacturing
37
Production Flow Analysis

PFA is a method for identifying part
families and associated machine groupings
that uses the information contained on
production route sheets rather than part
drawings.
Parts with identical or similar routings are
classified into part families.
Anan Mungwattana

Manufacturing
38
Production Flow Analysis

PFA uses mfg data to identify part families:
Parts whose basic geometrics are quite different
may require similar or identical routings.
Parts whose basic geometrics are quite similar
may require different routings.
Anan Mungwattana

Manufacturing
39
Procedure in PFA
Data collection:
The part number and operation sequence.
Lot size, cycle time, demand.
PFA chart
Part-machine incidence matrix
Sortation of process routings:

Parts are arranged into groups according to the
similarity of their process routings.
Anan Mungwattana

Manufacturing
40
Cellular Manufacturing is an application of
group technology (GT).
A composite part for a given family
includes all of the design and mfg attributes
of the family.
Anan Mungwattana

Manufacturing
41
Composite Part
Composite part concept: (a) the composite part for a

family of machined rotational parts, and (b) the
individual features of the composite part
Anan Mungwattana

Manufacturing
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Composite Part
1.
2.
3.
4.
Design feature
External cylinder
Face of cylinder
Cylindrical step
Smooth surface
5. Axial hole
6. Counterbore
7. Internal threads
Anan Mungwattana
Corresponding operation
Turning
Facing
Turning
External cylindrical
grinding
Drilling
Counterboring
Tapping

Manufacturing
43
There is always a correlation between part
design features and production operations
required to generate those features.
A production cell designed for those
machines required to make the composite
part.
Anan Mungwattana

Manufacturing
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CM involves
the formation of part families based upon their
similar processing requirements, and
the grouping of machines into mfg cells
A mfg. cell consists of several functionally

dissimilar machines which are placed in
close proximity to one another and
dedicated to the manufacture of a part
family.
Anan Mungwattana

Manufacturing
45
Breaks up a complex mfg into groups of cells,
each being dedicated to the processing of a part
family.
Material flow is simplified.

Scheduling tasks is easier.
Parts travel less.
Less space required.
Fewer machines needed.
Reduce set-up time (quicker response).
Reduce WIP, throughput time, lot sizes.
Anan Mungwattana

Manufacturing
46
Setup Time and Lot Size

Lot Size
Process Time
(min)
Setup (hr)
10
100
1,000
10,000
Anan Mungwattana

Manufacturing
Total Pro.
Time/unit
47
Setup Time and Lot Size

Lot Size Setup (Min)
Process Time
(min)
10
100
1,000
10,000
Anan Mungwattana

Manufacturing
Total Pro.
Time/unit
48
Anan Mungwattana

Manufacturing
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Design of CM
Layout in CM
Planning of CM
Control of CM
Anan Mungwattana

Manufacturing
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Design of Cellular Manufacturing

1. Part families are formed according to their
processing requirements.
2. Machines are grouped into manufacturing
cells.
3. Part families are assigned into cells.
4. Selection of tools, fixtures and pallets.
5. Selection of material handling equipment.
6. Layout of CM
Anan Mungwattana

Manufacturing
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Evaluation of Cell Design
Inter-cell material handling cost

Equipment and tools investment
Set-up time
Equipment utilization
Throughput time
WIP inventory
Queue length
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Manufacturing
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1
1
2 1
3
4 1
Part No.
2 3 4
1
1
1
1
1
1
5
1
Mc 2
No. 4
1
3
Part No.
1
3 2 4
1
1
1
1
1 1
1 1
(These tables are called machine-part incident matrix)
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Manufacturing
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Design Solution Strategies

1. Part family grouping solution strategy Part
families are formed first, then machines are
grouped in to cells according to the part families.
2. Machine grouping solution strategy Mfg cells
are created first based on similarity in part
routing, then parts are allocated to the cells.
3. Simultaneous machine-part grouping strategy
Part families and cells are formed
simultaneously.
Anan Mungwattana

Manufacturing
54
CM Design Methods
Array-based clustering
Similarity coefficiency
Graph partitioning approach
Mathematical programming
Heuristic search approach
AI-based approach
Anan Mungwattana

Manufacturing
55
CM Design Methods
Each design method considers different
design objectives and constraints, to
different extent, depending upon the scope
and interest of each design approach.
Some consider only part operations and
sequences, other may consider production
data.
Anan Mungwattana

Manufacturing
56
Rank Order Clustering Algorithm
1.
2.
3.
4.
Based on sorting rows and columns of the

machine-part incidence matrix
Assign binary weight and calculate a decimal
weight for each row and column using the
formulas
Rank the rows in order of decreasing decimal
weight values
Repeat 1 and 2 for each column
Continue the process until no more change in row
and column
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Manufacturing
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Example
Step1
32
16
8
4
2
1
5
4
3
2
1
0
Anan Mungwattana
P1
P2
P3
P4
P5
P6
6
64
M1
1
5
32
M2
1
4
16
M3
3
8
M4
1
2
4
M5
0
1
M7
1
1
1
2
M6
1
1
1
1
1
Manufacturing
1
1
74
52
10
48
17
37
58
Example
Step2
32
16
8
4
2
1
5
4
3
2
1
0
P1
P2
P4
P6
P5
P3
M1
1
1
1
1
M3
M4
1
M5
1
1
M6
1
28
26
M7
1
1
1
1
32
Anan Mungwattana
M2
1
33

Manufacturing
20
1
33
74
52
48
37
17
10
6
59
Example
Step3
P1
P2
P4
P6
P5
P3
M4
1
M6
1
M1
1
M2
1
1
1
M3
1
1
M5
1
1
1
1
20
1
1
33
Anan Mungwattana
1
33
32
28
26

Manufacturing
M7
112
14
12
11
5
96
60
Example
Step4
P1
P3
P2
P4
P6
P5
M4
1
1
M6
1
1
M1
1
M2
1
1
1
48
Anan Mungwattana
48
32
14
M3
1
1
M5
1
1
1
13

Manufacturing
M7
10
1
1
3
112
96
14
12
11
5
61
Observations
Do not incorporate production data such as
processing times, demand, costs, machine
capacity, operation sequences, etc.
May not always be able to get independent
cells
Depends upon initial incidence matrix
Cells and part families are formed naturally
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Types of Part Movement

Repeat Operation
A consecutive operation is carried out on the
same machine (part actually does not move).
In-sequence move
A part moves from the current machine to an
immediate neighbor in the forward direction.
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Types of Part Movement

By-pass move
A part moves forward from the current machine
to another machine that is two or more ahead.
Backtracking move
A part moves from the current machine in the
backward direction to another machine.
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GT Layout
GT flow line layout
same sequence
same amount of time on each machine
a mixed-product assembly line system.
GT cell layout
parts move from any machine to any other machine
machines are located in close proximity
GT center layout
a logical arrangement of machines
each machine is dedicated to make certain part families
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Manufacturing
65
Arranging Machines in Cell

To organize machines into the most logical
arrangement.
Two methods
Hollier method 1
Hollier method 2
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Hollier Method 1
Develop the From-to chart from part routing
data.
Indicates number of part moves between
machines into cell.
Determine the From and To sums for

each machine.
Accomplish by summing all of the From trips
and To trips for each machine.
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67
From-To Chart
Part
Demand
Sequence
30 A-C-B-D-E
12 A-B-D-E
3
Anan Mungwattana
7 A-C-D-B-E
Manufacturing
68
Hollier Method 1
Assign machines to the cell based on
minimum From or To sums.
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, the
machine is placed at the end of the sequence.
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Hollier Method 1
Tie breaker rules.
If a tie occurs between minimum To sum or
minimum From sum, then the machine with the
minimum From/To ratio is selected.
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.
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.
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Hollier Method 1
Reformat the From-To chart.
Restructure the From-To chart by eliminating
the row and column corresponding to the
selected machine.
Recalculate the From and To sums.
Repeat until all machines have been assigned.
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71
Hollier Method 1
From/To
25
30
15
10
40
10
Anan Mungwattana

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72
Hollier Method 1
To
From
Sum
25
30
30
15
45
10
40
50
10
10
To Sum
50
45
40
135
From
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Hollier Method 1
To
From
Sum
25
30
30
15
45
10
10
To Sum
40
40
From
Anan Mungwattana

Manufacturing
74
Hollier Method 1
To
From
From Sum
25
25
10
10
To Sum
10
25
Anan Mungwattana

Manufacturing
75
Hollier Method 2
Determine the From-To chart.
Determine the From-To chart ratio for each
machine.
Arrange machines in order of decreasing
From/To ratio.
Anan Mungwattana

Manufacturing
76
Hollier Method 2
To
From
From
sum
Ratio
25
30
0.60
30
15
45
1.00
10
40
50
10
10
0.25
To
Sum
50
45
40
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Manufacturing
77
Performance Measures
Percent of in-sequence moves
Computed by adding all of the values
representing in-sequence moves dividing by the
total number of moves.
Percent of backtracking moves

Determined by summing all of the values
representing backtracking moves and dividing
by the total number of moves.
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78
Performance Measures
Sequence 3 2 1 4
% In Sequence = (40+30+25)/135 = 70.4%
% Backtrack = (5+10)/135 = 11.1%
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Manufacturing
79
HW.
To
From
10
80
C
D
E
Anan Mungwattana
85
-
70
20
75
Manufacturing
20
80
Arrangement in Cell
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Arrangement in Cell
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Arrangement in Cell
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Arrangement in Cell
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Arrangement in Cell
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Arrangement in Cell
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Arrangement in Cell
Anan Mungwattana

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Arrangement in Cell
Anan Mungwattana

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Arrangement in Cell
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Group Technology and Cellular Manufacturing: Anan Mungwattana

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Group Technology and

Order preparation time

Group Technology and Cellular

14% - set-up time

Group Technology and Cellular

Reduced product life cycles

Mfg systems must have a product range which

Group Technology and Cellular

Group Technology and Cellular

Job Shop Manufacturing System

Group Technology and Cellular

Flow Shop Manufacturing System/

Group Technology and Cellular

Cellular Manufacturing System/

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Operation Sequence / Time

M1 (2) M2 (3) M3 (1)

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Rearranging production machines into machine

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Group Technology and Cellular

Part Classification and Coding

Group Technology and Cellular

Part Classification and Coding

Group Technology and Cellular

Part Classification and Coding

Group Technology and Cellular

Part Classification and Coding

Group Technology and Cellular

Part Classification and Coding

Group Technology and Cellular

Part Classification and Coding

Group Technology and Cellular

Part Classification and Coding

Group Technology and Cellular

Group Technology and Cellular

Opitz Classification System

Group Technology and Cellular

Opitz Classification System

The first nine digits are intended to convey

Group Technology and Cellular

Opitz Classification System

Group Technology and Cellular

Opitz Classification System

Digit 1: Part class

Group Technology and Cellular

Opitz Classification System

Group Technology and Cellular

Opitz Classification System

Group Technology and Cellular

Production Flow Analysis

Group Technology and Cellular