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043_Cellular Layout & Part Family Identification

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The objectives of this module are to: explain the purpose of Cellular Layout and its benefits, understand the different types of Cellular Layouts, understand the pro?s and con?s of each type of Cellular Layout, use this approach in designing a cell, understand the process and rationale of grouping parts into families and machines into cells to accomplish a lean environment.

This module is 59 slides and the material is suitable for independent study or formal classroom training and includes an exercise and quiz questions.

Published in: Business
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043_Cellular Layout & Part Family Identification

  1. 1. 1 Cellular Layout & Part Family Identification 1
  2. 2. 4 Creation of Flow and Cell Design ● What is Flow? Analogous to a river Concerns both macro and micro process steps Product must move smoothly from raw material to finished product Sequence of operations must follow each other Produce in batches of one when possible Flow Defined The progressive achievement of tasks along the value stream so that a product proceeds from design to launch, order to delivery, and raw materials into the hands of the customer with no stoppages, scrap, or back flows.* * Womack, J. P. and D. T. Jones, 1996, Lean Thinking, Simon & Schuster This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  3. 3. 7 Evolution of Layouts Over time process flows have continued to change in order to maximize key metrics… Types of Layouts: • One to One • Bird Cage • Isolated Island • Linear Layout • U-Turn Cells • Multiple U-Turn cells This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  4. 4. 10 Bird Cage Layouts Bird Cage - One person assigned to One Type of equipment DRILL LATHE LATHE LATHE LATHE This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  5. 5. 13 Isolated Island Pros & Cons • Advantages Cross-functional resources Productivity of person typically increases • Disadvantages People are separate & cannot help each other Difficult to respond to small changes in demands Overall productivity is not as positively impacted More training required This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  6. 6. 16 U-Turn Cells Layout Start End ● U-Turn Cell - People assigned to multiple types of equipment. People and materials, move from station to station. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  7. 7. 19 Multiple U-Turn cells ● BIG ADVANTAGE ** The area becomes more efficient, as fractional parts of a person can be spread among all cells! 5 People 6 cells Adjustments in required output can be easily done!! This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  8. 8. 22 Designing Cells ● Elements to be considered: Manpower Machines Materials Methods Environment ● Need to answer these questions: What equipment should go into the cell? What items or processes should be produced in cells? How should people operate the cell? Where should materials be placed? This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  9. 9. 25 Cellular Design Roadmap P-Q Analysis - 500 1,000 1,500 2,000 2,500 3,000 B 2 0C6 C 1 0 B 3 C 30 D2 A 2 0 C 5 B 3 0D 1D 1 0 B 4 A 30 D 9 D 3 0 D 3 C 1 0B 3 A1 0 B 1 C 2 0C 7D 20 C8 B10 B 2 Volume 0% 20% 40% 60% 80% 100% 120% Cummulative% P-Q Analysis - 500 1,000 1,500 2,000 2,500 3,000 B 2 0C6 C 1 0 B 3 C 30 D2 A 2 0 C 5 B 3 0D 1D 1 0 B 4 A 30 D 9 D 3 0 D 3 C 1 0B 3 A1 0 B 1 C 2 0C 7D 20 C8 B10 B 2 Volume 0% 20% 40% 60% 80% 100% 120% Cummulative% ● Product Quantity Analysis – initially narrow down opportunities based on volume ● Demand Segmentation – narrow down further and segment based on volume and variability ● Decomposition Methods – group parts by physical characteristics ● Product/Process matrix – group parts and equipment into cells 1 2 3 4 8 5 6 7 9 10 11 12 14 13 15 16 17 18 Machines PartC PartM PartA PartR PartE PartL PartT PartF PartQ PartB PartK PartP PartS PartG PartD PartH PartN PartJ Power Weight Rank 1 102-B 1 1 1 1 2 282 1 2 107-G 1 1 1 1 4 284 2 3 108-H 1 1 1 1 8 284 2 4 103-C 1 1 1 1 1 16 17120 4 5 106-F 1 1 1 1 1 32 23680 5 6 105-E 1 1 1 1 1 1 64 23744 6 7 101-A 1 1 1 1 1 128 319744 7 8 104-D 1 1 1 1 1 1 1 1 1 256 491008 8 9 109-J 1 1 1 1 512 491520 9 10 110-K 1 1 1 1 1024 491520 9 Power 2 4 8 16 256 32 64 128 512 1024 2048 4096 16384 8192 32768 65536 131072 262144 Weight 2 12 14 14 142 16 80 112 272 352 352 352 496 384 1664 1792 1792 1920Rank 1 2 3 3 8 5 6 7 9 10 10 10 14 13 15 16 16 18 Analyze Identify Implement This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  10. 10. 28 Cell Design Considerations ● Tools and Materials Should Be: Placed for the operator’s convenience Placed closely to and in front of the operator Kept in designated place ● Work Station Design Bench height designed for operator and nature of work Lighting best suited for the operator and the work Minimum travel distance between operations Standing preferred for flexibility ● Material Movement: Avoid vertical transfers Move objects horizontally Use gravity to move objects ● Address Ergonomic Issues Layout and Equipment All oils, water, electrical, air, gas, etc. should be plumbed/piped to the point of use This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  11. 11. 31 Visual Layout - Work Cells Design of the cell should be “Visual” Ask: Can a person see everything from one point? Can they quickly observe abnormalities? Is the work area designed for visual systems? Are areas identified where materials are stored? Where is raw material stored? - How much? Look for opportunities to add Visual indicators wherever possible. Lines on floors Color coding containers or folders Shadow boards or outlined areas for locating equipment This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  12. 12. 34 Keys to Success ● Include process personnel on the Design Team. ● Have Cross Functional representation on the Team. ● Be creative to overcome industry/company specific challenges. ● Address sources of process variation - time and quality variation. ● Design flexibility into the process. ● Keep things simple! ● Apply only where it is appropriate. ● Break old paradigms. ● Challenge, Challenge, Challenge, question everything - find “root causes” for “why it must be that way”. This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  13. 13. 37 Cellular Design Roadmap P-Q Analysis - 500 1,000 1,500 2,000 2,500 3,000 B 2 0C6 C 1 0 B 3 C 30 D2 A 2 0 C 5 B 3 0D 1D 1 0 B 4 A 30 D 9 D 3 0 D 3 C 1 0B 3 A1 0 B 1 C 2 0C 7D 20 C8 B10 B 2 Volume 0% 20% 40% 60% 80% 100% 120% Cummulative% P-Q Analysis - 500 1,000 1,500 2,000 2,500 3,000 B 2 0C6 C 1 0 B 3 C 30 D2 A 2 0 C 5 B 3 0D 1D 1 0 B 4 A 30 D 9 D 3 0 D 3 C 1 0B 3 A1 0 B 1 C 2 0C 7D 20 C8 B10 B 2 Volume 0% 20% 40% 60% 80% 100% 120% Cummulative% ● Product Quantity Analysis – initially narrow down opportunities based on volume ● Demand Segmentation – narrow down further and segment based on volume and variability ● Decomposition Methods – group parts by physical characteristics ● Product/Process matrix – group parts and equipment into cells 1 2 3 4 8 5 6 7 9 10 11 12 14 13 15 16 17 18 Machines PartC PartM PartA PartR PartE PartL PartT PartF PartQ PartB PartK PartP PartS PartG PartD PartH PartN PartJ Power Weight Rank 1 102-B 1 1 1 1 2 282 1 2 107-G 1 1 1 1 4 284 2 3 108-H 1 1 1 1 8 284 2 4 103-C 1 1 1 1 1 16 17120 4 5 106-F 1 1 1 1 1 32 23680 5 6 105-E 1 1 1 1 1 1 64 23744 6 7 101-A 1 1 1 1 1 128 319744 7 8 104-D 1 1 1 1 1 1 1 1 1 256 491008 8 9 109-J 1 1 1 1 512 491520 9 10 110-K 1 1 1 1 1024 491520 9 Power 2 4 8 16 256 32 64 128 512 1024 2048 4096 16384 8192 32768 65536 131072 262144 Weight 2 12 14 14 142 16 80 112 272 352 352 352 496 384 1664 1792 1792 1920Rank 1 2 3 3 8 5 6 7 9 10 10 10 14 13 15 16 16 18 Analyze Identify Implement This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  14. 14. 40 1. Visual Method 2. Coding Method Visual Method Other Clustering Methods Before Visual Classification PF - 1 PF - 3 PF - 4 PF - 2 After Visual Classification This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  15. 15. 43 • The Product/Process Matrix leads to grouping parts into part families (PF) and machines into machine cells (MC) • The result of this grouping is implemented as physical cellular machine layout Product/Process Matrix 1 2 3 4 8 5 6 7 9 10 11 12 14 13 15 16 17 18 Machines PartC PartM PartA PartR PartE PartL PartT PartF PartQ PartB PartK PartP PartS PartG PartD PartH PartN PartJ Power Weight Rank 1 102-B 1 1 1 1 2 282 1 2 107-G 1 1 1 1 4 284 2 3 108-H 1 1 1 1 8 284 2 4 103-C 1 1 1 1 1 16 17120 4 5 106-F 1 1 1 1 1 32 23680 5 6 105-E 1 1 1 1 1 1 64 23744 6 7 101-A 1 1 1 1 1 128 319744 7 8 104-D 1 1 1 1 1 1 1 1 1 256 491008 8 9 109-J 1 1 1 1 512 491520 9 10 110-K 1 1 1 1 1024 491520 9 Power 2 4 8 16 256 32 64 128 512 1024 2048 4096 16384 8192 32768 65536 131072 262144 Weight 2 12 14 14 142 16 80 112 272 352 352 352 496 384 1664 1792 1792 1920 Rank 1 2 3 3 8 5 6 7 9 10 10 10 14 13 15 16 16 18 This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  16. 16. 46 Decomposition Algorithm This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  17. 17. 49 2. Select Row # 1 In The Matrix and draw a horizontal line (Use Green line) Parts Machi nes Part#1 Part#2 Part#3 Part#4 Part#5 Part#6 Part#7 Part#8 Machine #1 1 1 1 Machine #2 1 1 Machine #3 1 1 Machine #4 1 1 Machine #5 1 1 1 Machine #6 1 Machine #7 1 1 1 1 This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  18. 18. 52 5. Repeat Steps: 7.3 & 7.4 Until No More Crossed “1” Crossed Once. All Crossed Twice Form Potential Projects That May or May Not Decomposed Further Depending on the Constraints. Parts Machi nes DP#1 DP#2 DP#3 DP#4 DP#5 DP#6 DP#7 DP#8 Machine #1 1 1 1 Machine #2 1 1 Machine #3 1 1 Machine #4 1 1 Machine #5 1 1 1 Machine #6 1 Machine #7 1 1 1 1 This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  19. 19. 55 7.b. Repeat The Process For Submatrix 1.2. Parts Mach ines Part#1 Part#4 Part#6 Part#7 Machin e#2 1 1 Machin e#3 1 1 Machin e#4 1 1 Machin e#6 1 += Parts Mach ines Part#1 Part#6 Machin e#2 1 1 Machin e#4 1 1 Parts Mach ines Part#4 Part#7 Machin e#3 1 1 Machin e#6 1 Table 1.2.1: Crossed Matrix Table 1.2.2: Left-Over Matrix This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
  20. 20. 58 Tools None specific to this module This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/043cellular-layout-and-part-family-identification-1143
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