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cellular_manufacturing_presentation_20250821135220.pptx
- 1. Cellular Manufacturing Principles, Implementation& Custom Cell Design A comprehensive overview of cellular manufacturing, its evolution, core principles, industry case studies, and a detailed electronic assembly cell design August 21, 2025 Presented by: Manufacturing Excellence Team Made with Genspark
- 2. Introduction & Definition Whatis Cellular Manufacturing? Cellular manufacturing is a lean production approach where equipment and workstations are arranged in cells dedicated to manufacturing similar product families. Each cell contains all the machinery, tools, and operators needed to produce a complete product or component from start to finish. Core Characteristics Group technology principles (product families) One-piece flow focused production U-shaped or dedicated cell layouts Multi-skilled, cross-trained operators Minimized material handling and transport Key Benefits Reduced Lead Time 30-70% shorter production cycles Higher Quality Immediate defect detection Less WIP Reduced inventory by 60-80% Improved Flexibility Easier adaptation to demand changes U-Shaped Cell Flow Direction Made w2ith Genspark
- 3. Evolution from Traditionalto Cellular Manufacturing Traditional Manufacturing Drilling Dept Milling Dept Assembly Dept Welding Dept Painting Dept Quality Dept Cellular Manufacturing Cell 1: Product Family A Cell 2: Product Family B Cell 3: Product Family CCell 4: Product Family D Feature Layout Traditional Manufacturing Cellular Manufacturing Product-focused cells with all necessary equipment for a product family Functional departments with similar machines grouped together Material Flow Long distances, complex paths, high transportation waste Short distances, streamlined flow, minimal movement Batch Size Large batches to maximize equipment utilization Small batches or one-piece flow for flexibility Work-in-Progress High WIP levels between departments Minimal WIP with continuous flow
- 4. Key Principles andConcepts Cellular manufacturing is built on several fundamental principles that work together to create an efficient, flexible, and quality-focused production system. Group Technology Identifying and grouping similar parts into families based on design attributes or processing requirements, allowing specialized cells to handle specific part families efficiently One-Piece Flow Moving products through each operation one unit at a time, eliminating batches and reducing lead time, WIP inventory, and defect propagation Cross-Trained Workforce Operators trained to perform multiple tasks within a cell, improving flexibility, balancing workload, and increasing workforce engagement Integrated Cellular Manufacturing Principles Continuous Improvement Ongoing effort to improve products, services, and processes through incremental improvements or breakthrough innovations (Kaizen) Waste Elimination Identifying and eliminating the 7 wastes (Muda): Overproduction, Waiting, Transportation, Processing, Inventory, Motion, and Defects Group Technology One-Piece Flow Waste Elimination C r o s s - T r a i n i n g C e l l u l a r M a n u f
- 5. Types of CellLayouts Cellular manufacturing employs various layout configurations, each optimized for specific product types, process flows, and space constraints. The right layout choice significantly impacts productivity, material flow, and operational efficiency. U-Shaped Cell Most common and efficient design Minimal operator movement Facilitates cross-training Enhanced communication Linear (I-Shaped) Cell Simple, sequential processes Efficient for straightforward flows Minimal backflow Good for limited space areas T-Shaped Cell For processes with multiple inputs Subassemblies join main assembly Efficient material convergence Supports divergent product variants O-Shaped Cell (Cage) Single operator at center Suitable for multiple reuse equipment Products may require multiple passes S-Shaped Cell Works around facility obstructions Adapts to existing fixed equipment Optimizes space utilization
- 6. Benefits and Advantages Cellularmanufacturing delivers significant improvements across key operational metrics, resulting in a more efficient, flexible, and quality- focused production environment. Reduced Lead Time Shorter production cycles with reduced waiting, transportation, and processing time. 30-70% Lead time reduction compared to traditional manufacturing Reduced WIP Minimized inventory between processes due to continuous flow production. 60-80% Reduction in work-in-progress inventory Quality Improvement Immediate defect detection prevents cascade of quality issues through production. 25-50% Reduction in defect rates and rework Space Utilization Up to 40% reduction in required floor space Operator Engagement Increased ownership and multi- skilling of workforce Production Flexibility Ability to quickly adapt to product variations and volume changes Cost Reduction 20-30% overall manufacturing cost savings Made w6i t h Genspark
- 7. Implementation Process andSteps Step-by-Step Implementation Implementation Flowchart START: Current State Analysis Identify Part Families Pilot Successful? No: Refine Yes Full Implementation Design Cell LayoutContinuous Improvem Key Implementation Considerations Stakeholder Involvement Include operators in design phase Metrics Tracking Establish KPIs for before/after 1 Analyze Current State Conduct value stream mapping and process analysis to identify waste and improvement areas 2 Identify Part Families Group similar products based on design features, process requirements, and routing sequences 3 Design Cell Layout Create U-shaped or optimal layout configurations that minimize movement and maximize flow 4 Cross-Train Operators Develop multi-skilled workforce capable of handling multiple processes within the cell 5 Pilot and Refine Implement pilot cell, gather data and feedback, and make necessary adjustments
- 8. Case Studies: Automotive& Electronics Automotive Composite Parts Manufacturer A manufacturer of automotive composite parts implemented cellular manufacturing to enable flexible production of customized components while maintaining volume output. Implementation Highlights Transition from traditional production line to cellular manufacturing Implementation of robotic trimming cells with rapid set-up capability Integration of IONA metrology system for precision alignment Cross-training of operators across different cell operations Results & Metrics Setup Time Reduced by 65% Flexibility Any part on any machine Electronics PCB Assembly A global electronics manufacturer implemented cellular manufacturing for their PCB assembly process to address inefficiencies, bottlenecks and quality issues. Implementation Highlights U-shaped cells designed for different PCB types and product families Cross-trained operators managing multiple processes within each cell Real-time quality monitoring and feedback system integration Automated material delivery to each cell with kanban signals Results & Metrics Lead Time Reduced by 48% WIP Inventory First Pass Yield Improved to 99.2% Floor Space
- 9. Challenges and Solutions Implementingcellular manufacturing brings significant benefits but also presents several challenges. Here's how to address the most common obstacles: Robust Preventive Maintenance Implement Total Productive Maintenance (TPM) strategies with operator- level maintenance activities. Invest in backup critical components and quick- change tooling to minimize downtime impact. Time Studies and Cross-Training Conduct detailed time studies to identify imbalances. Implement cross- training so operators can float to bottleneck areas as needed. Design cells with flexible staffing patterns to accommodate varying workloads. Inclusive Implementation Involve workers in the cell design process. Provide comprehensive training on both technical skills and the principles of cellular manufacturing. Start with pilot cells to demonstrate success before full implementation. Phased Implementation Equipment Downtime Bottlenecks When a single machine in a cell breaks down, it can halt the entire cell's production. Unlike process layouts where alternative machines may be available, cells typically have one of each machine type. Balancing Workload Achieving balanced workloads across all operations in a cell is difficult, leading to operators waiting or stations being idle while others become bottlenecks. Change Resistance Workers accustomed to traditional manufacturing methods may resist the transition to cellular manufacturing, especially if it requires new skills or changes established working relationships. Initial Investment
- 10. Custom Cell DesignExample: Electronic Component Assembly Equipment Specifications Automated SMT pick & place machine Reflow soldering station with temperature control AOI (Automated Optical Inspection) system Functional circuit testers ESD-protected workstations Component storage & retrieval system Personnel Requirements 4 cross-trained operators per shift Skills required: PCB assembly, soldering, testing Rotating positions every 2 hours One team leader overseeing cell operation Cross-training matrix for all positions Performance Metrics Cycle time: 3-5 minutes per PCB assembly Daily output: 90-120 completed units First pass yield: 98.5% target Defect rate: <0.5% after final QC Changeover time: 15-20 minutes between product variants OEE (Overall Equipment Effectiveness): 85% PCB Preparation Component Picking Component Placement Soldering Testing Final Assembly Quality Control Packaging U-Shaped Electronic Component Assembly Cell Operator Position Workstation
- 11. Future Trends &Conclusion Emerging Trends Advanced Automation & Robotics Collaborative robots (cobots) within cells, automated material handling, and real-time production monitoring systems Industry 4.0 Integration IoT-enabled smart cells with connected equipment, digital twins, cloud-based manufacturing systems Data Analytics & AI Predictive maintenance, production optimization, quality control, and autonomous decision-making within cells Sustainable Manufacturing Energy-efficient cells, waste reduction, resource optimization, and circular economy approaches Key Takeaways 1 Transformation Journey Cellular manufacturing represents a significant shift from traditional manufacturing—requiring cultural change, technical adaptation, and continuous improvement mindset 2 Competitive Edge Organizations implementing cellular manufacturing gain advantages in quality, flexibility, cost, and responsiveness to market changes 3 Implementation Success Success depends on proper planning, analysis, employee engagement, and a phased approach—with emphasis on part families and flow optimization 4 Future Ready Cellular manufacturing provides the foundation for adopting advanced technologies and adapting to future manufacturing challenges