Manufacturing cell design

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Manufacturing cell design

  1. 1. M. S. Ramaiah School of Advanced Studies 1BySreejesh SP – BUB041200521 stApril 2013Module: Lean Operation and Management of leanorganizationModule Leader: Mr. Sandeep .NM. Sc. ( Engg.) in Engineering andManufacturing ManagementManufacturing Cell Design & LeanPrinciples
  2. 2. M. S. Ramaiah School of Advanced Studies 2Aim :This presentation aims on the study of how the cell manufacturingdesigns helps to implement the lean culture.Objective :The main objectives of this presentation are•Understanding the principles of lean.• Knowing the importance of cellular manufacturing in an industry.•Also to check how the implementation of cellular layout can help theorganization to become more lean.Aim & Objective
  3. 3. M. S. Ramaiah School of Advanced Studies 35 LeAN priNcipLesValue - specify what creates value from the customer’s perspective.The value stream – identify all the steps along the process chain.Flow - make the value process flow.Pull - make only what is needed by the customer (short term response to thecustomer’s rate of demand).Perfection - strive for perfection by continually attempting to produce exactlywhat the customer wants.
  4. 4. M. S. Ramaiah School of Advanced Studies 4Note : POUS – Point of Use storageLeAN buiLdiNg bLOcks
  5. 5. M. S. Ramaiah School of Advanced Studies 5Cellular Flow Manufacturing is a method oforganizing manual and machine operations inthe most efficient combination to maximizevalue-added content and minimize waste.…is a lean manufacturing approach thathelps companies build a variety of productsfor their customers with as little waste aspossible.defiNitiON
  6. 6. M. S. Ramaiah School of Advanced Studies 6AdvANtAges/disAdvANtAgesAdvantages:• Reduce material handling•Reduce tooling•Reduced set-up times•Reduced expediting•Reduced in-processinventory•Improved human relationsImproved operator expertiseDisadvantages:• Increased capital investment• Lower M/C utilization• Labor resistance (need for crosstraining and flexibility)
  7. 7. M. S. Ramaiah School of Advanced Studies 7One Piece Flow…is a condition that exists whenproducts move through a manufacturingprocess one unit at a time, at a ratedetermined by the needs of thecustomer.
  8. 8. M. S. Ramaiah School of Advanced Studies 8Operating in a U-Shaped Cell• Reduce travel distanceby arranging equipmentand workstations closertogether.• Beginning of process iscloser to end ofprocess….minimizes thetravel distance for nextcycleinput outputCell Lay-Out
  9. 9. M. S. Ramaiah School of Advanced Studies 9StepS of Cell DeSign1. Document the current process2. Define the product family and calculateTAKT Time.3. Balance the work to create flow betweenwork-stations that meets demand4. Design the cell for ergonomics5. Test and de-bug the cell design
  10. 10. M. S. Ramaiah School of Advanced Studies 10CaSe StUDYArvin Electronics Inc. was established in 1997 inEurope. It was incorporated keeping a simple vision“giving customer power of choice to choose fromvaried range of quality products with good after-salessupport and service at affordable price”. The wholeidea was to give true value for money.Cell design change at ARVIN Electronic Inc.
  11. 11. M. S. Ramaiah School of Advanced Studies 11Operation carried out by 6 operatorBend Pipe andtrim inlet endHeat and forminlet endSize andinspect/testflange and productassemblyWeld flangebrackets andassemblyDimension checkand leak test
  12. 12. M. S. Ramaiah School of Advanced Studies 12Layout
  13. 13. M. S. Ramaiah School of Advanced Studies 13First pass work cell design… 3 people
  14. 14. M. S. Ramaiah School of Advanced Studies 14Second try – work cell design – 1 person
  15. 15. M. S. Ramaiah School of Advanced Studies 15RESULTSBEFORE
  16. 16. M. S. Ramaiah School of Advanced Studies 16After ( first pass with 3 operator)
  17. 17. M. S. Ramaiah School of Advanced Studies 17RESULTS (contd.) Floor space reduction nearly 50% Customer rejects reduced 95% Scrap reduced 62% Work in process reduced 91%Changeover time reduced by 78%Labor cost as % of sales reduced 41%(Documented savings )(ref:www.innomet.ee/innomet/ERPKoolitus/1.JIT_Solution.ppt )
  18. 18. M. S. Ramaiah School of Advanced Studies 18ConCLUSion•The cell designing helps the organization to become more lean.•The case study at Arvin electric clearly shows the variousbenefits of implementing cellular manufacturing for theorganization as well as the customer.•This type of layout helps in proper flow of material parts whichin turn reduces the inventory.•All the 5 principle of lean i.e. Value, The value stream, Flow,Pull and Perfection is followed by modifying the cell layout.
  19. 19. M. S. Ramaiah School of Advanced Studies 19SUMMARY• 5 Lean Principles•Cellular manufacturing definition.•Advantages and disadvantages.•Steps involved in shifting from a traditional layout tocellular layout•Benefits of implementing cellular layout at ArvinElectric Inc.
  20. 20. M. S. Ramaiah School of Advanced Studies 20
  21. 21. M. S. Ramaiah School of Advanced Studies 21

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