The document discusses the implementation of cellular manufacturing at Pakistan Spring & Engineering Co. It aims to shorten lead times, reduce inventory, improve quality, simplify production scheduling and reduce setup time. It proposes organizing machines into cells based on the parts and operations. It analyzes the production operations and recommends forming two cells - a U-shaped cell for the first cluster with in-sequence moves and a rectangular cell for the second cluster with backtracking moves. This would significantly reduce transportation and motion waste.

1. At Pakistan Spring & Engineering Co. (Ltd.)

2. • To shorten lead times
• To reduce inventory
• To improve quality
• To simplify Production scheduling
• To reduce setup time

3.  Producing according to Takt Time (Line Balancing)
 Planning of layout must be feasible in order to cater
the cells made
 Pull system has to be integrated to the parts that are
to be arranged in a cell (Kanban)
 Individual Changeover times of machines must be
reduced to a minimum in order to benefit from
cellular manufacturing

5. • Body C CD 70 cc
• Seat Spring
• Mouth Collar
• Plate Baffle
• Main Plate for Honda CG 125
• Suzuki pickup steering spoke

12. Machine names with processes
Blanking on shearing press
Blanking on power press
1st Draw on Hydraulic Press
2nd Draw on Hydraulic Press
Cutting on Lathe
Facing on Lathe
Trimming on Power Press
Bending on Power Press
Punching on Pneumatic Press
Piercing on Power Press

14. A. Body C CD 70 cc 2-3-4-6-7 2000
B. Seat Spring 2-3-6-7 2500
C. Mouth Collar 5-8-9 5000
D. Plate Baffle 2-3-4-7 3000
E. Main Plate for Honda CG 125 1-9-8 2500
F. Suzuki pickup steering spoke 1-9-10-8 2500

15. Operation
Code
Machine names with processes
1 Blanking on shearing press
2 Blanking on power press
3
1st Draw on Hydraulic Press
4 2nd Draw on Hydraulic Press
5 Cutting on Lathe
6 Facing on Lathe
7 Trimming on Power Press
8 Bending on Power Press
9 Punching on Pneumatic Press
10 Piercing on Power Press

17. Operations Parts
A B C D E F
1 I I
2 I I I
3 I I I
4 I I
5 I
6 I I
7 I I I I
8 I I I
9 I I I
10

19. Operations
Parts
Decimal Equivalent Rank32 16 8 4 2 1
A B C D E F
1 I I 3 9
2 I I I 52 1
3 I I I 52 2
4 I I 36 5
5 I 8 8
6 I I 48 4
7 I I I I 52 3
8 I I I 11 6
9 I I I 11 7
10 1 10

20. Operations
Parts
32 16 8 4 2 1
A B C D E F
2 I I I
3 I I I
7 I I I
6 I I
4 I I
8 I I I
9 I I I
5 I
1 I I
10 I

21. Operations Parts
A B C D E F
2 I I I 512
3 I I I 256
7 I I I 128
6 I I 64
4 I I 32
8 I I I 16
9 I I I 8
5 I 4
1 I I 2
10 I 1
Decimal
Equivalent
992 960 28 928 26 27
Rank 1 2 4 3 6 5

22. Operations
Parts
Decimal Equivalent Rank32 16 8 4 2 1
A B D C F E
2 I I I 56 1
3 I I I 56 2
7 I I I 56 3
6 I I 48 4
4 I I 40 5
8 I I I 7 6
9 I I I 7 7
5 I 4 8
1 I I 3 9
10 I 2 10

24. To
Operation
Code
Machine names with processes From
0 1 Blanking on shearing press 2500+2500
0 2 Blanking on power press 2000+2500+3000
2000+2500+3000 3 1st Draw on Hydraulic Press 2000+2500+3000
2000+3000 4 2nd Draw on Hydraulic Press 2000+3000
0 5 Cutting on Lathe 5000
2000+2500 6 Facing on Lathe 2000+2500
2000+3000+2500 7 Trimming on Power Press 0
5000+2500+2500 8 Bending on Power Press 5000
5000+2500+2500 9 Punching on Pneumatic Press 2500+2500
2500 10 Piercing on Power Press 2500

25. From
To
2 3 4 6 7 From sums
From/To
Ratio
2 0 7500 0 0 0 7500 ∞
3 0 0 5000 2500 0 7500 1
4 0 0 0 2000 3000 5000 1
6 0 0 0 0 4500 4500 1
7 0 0 0 0 0 0
To Sums 0 7500 5000 5000 7500 24500

26. 3 42 6 7
7500 7500
7500
2500
5000 2000
3000
4500

27. Percentage in sequence moves = 19000/24500*100 = 77.5%
Percentage By-Passing Moves = 5500/24500*100 = 22.5 %
Percentage Back Tracking Moves = 0/24500*100 = 0 %

28. From
To
1 5 8 9 10
From
sums
From/To
Ratio
1 0 0 0 5000 0 7500 ∞
5 0 0 5000 0 0 7500 ∞
8 0 0 0 5000 0 5000 0.5
9 0 0 2500 0 2500 4500 0.5
10 0 0 2500 0 0 0 1
To Sums 0 0 10000 10000 2500 22500

29. 5 101 8 9
5000 0 5000
2500
0 2500
5000
5000
5000
5000
5000
2500

30. Percentage in sequence moves = 7500/22500*100 = 33.33%
Percentage By-Passing Moves = 10000/22500*100= 44.44 %
Percentage Back Tracking Moves = 5000/22500*100 = 22.22 %

31.  2 cells are made comprising of 5 machines
The cells are type II M (Group machine cell with manual handling)
For 1st cluster U shaped layout is suggested (As there are in sequence moves)
For 2nd cluster rectangular layout is suggested (As there are back track moves)
There is a drastic reduction in the “transportation” and “motion” waste