Cellular manufacturing is an approach where equipment and workstations are arranged based on groups of similar manufacturing processes located close together. This reduces cycle times and inventories to meet market demands. Traditional straight line layouts can imbalance tasks, while cellular U-shaped layouts improve worker access. One-piece flow, multi-process handling, and multi-functional workforces increase flexibility. Layouts should minimize transit time between workstations by keeping them close together in linear order. This can save companies millions per year by reducing unnecessary operator travel time. Cellular manufacturing advantages include reduced inventory/space needs and costs as well as increased productivity.

1. Cellular
Manufacturing
Prepared by Reza Rahman
Manager, HRBP-PAL

2. What is Cellular Manufacturing
Cellular manufacturing is an approach in which all
equipment and workstations are arranged based on
an group of different processes located in close
proximity to manufacture a group of similar
products.
The primary purpose of cellular manufacturing is to
reduce cycle time and inventories to meet
market response times.

3. Layouts Using Work Cell
• Traditional layout
Straight lines make it hard to balance tasks because work may not be
divided evenly
• Cellular layout
Improved layout – in U shape, workers have better access. Four cross -
trained workers were reduced.

4. Types of Operations
One piece flow
Handling items one at a time eliminates wastes inherent
in batch production and enables a balanced flow of
work
Multi-process handling
Multi-process handling increases flexibility in the
process and avoids the inefficiencies inherent in
traditional manufacturing arrangement.
Multi-functional workforce
A multi-functional workforce is critical to enable flexible
operations where the range of tasks performed by a
given worker can be varied to match demand.

5. Types of Cell Layout

6. Three Rules of Optimization
Minimize transit time:
• Minimizing transit time is essential for improved productivity.
• It is crucial to understand that there are cycle times for a finished product
• There are individual cycle timer for each operation.
• As such, your cycle times relate to your transit times form one workstation
to the next, and from one cell to the next.

7. Simplify Workflow
• Work should move freely from one workstation to the next, within
the cell, and from one cell to the next.
• Cells should be stationed in a linear order for a logical and
consecutive flow
• operators should be able to move quickly and easily between
machines when necessary.

8. Functionality
• Operators shouldn’t be inhibited by tight corners;
• allow some free space and ensure they have enough area to move
around.
• Whether using personnel or automated material transport to move
goods, space should be kept free between workstations
• Allow easy maneuvering and efficient transport through the space.

9. Why is minimizing transit time so important in
manufacturing work cell design?
• It’s not uncommon to see operators manually moving parts from one location within the shop floor to the
other side of the warehouse.
• Operators are moving away from their station which can take anywhere from 40 seconds to several minutes.
• Doing small batches then moving materials every once and awhile doesn’t seem like a big deal, but over an
entire shift, this can lead to significant impact.
• In fact, here’s a post on how manual material transport could cost you $1M/year.

10. Minimize Transit Time With Industry 4.0 Technology
• The most common work cell layouts for optimized design are:
U, T, S, Z.
• All four of these work cell design layouts allow a streamlined
workflow process from one cell to the next.
• S and Z layouts are often used if and when obstructions like
CNC machines or pillars are in the way; they allow you to work
around these types of obstructions.
• In most environments, one of these four layouts would align
with both the process and the space available on the shop
floor. The layouts minimize transit time between cells because
the stations are positioned close together, and in a linear order.

11. Challenges While Implementation
• The biggest challenge when implementing cellular manufacturing in a
company is dividing the entire manufacturing system into cells.
• The issues may be conceptually divided in the “hard” issues of
equipment, such as material flow and layout, and the “Soft” issues of
management, such as up skilling and corporate culture.

12. Advantages of Work Cell (Cellular)
• Reduced work - in – process inventory
• Less floor space required
• Reduced raw material and finished goods inventory
• Reduced direct labor
• Heightened sense of employee participation
• Increased use of equipment and machinery
• Reduced investment in machinery and equipment

13. Thank you