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By
Sreejesh SP – BUB0412005
21 st
April 2013
Module: Lean Operation and Management of lean
organization
Module Leader: Mr. Sandeep .N
M. Sc. ( Engg.) in Engineering and
Manufacturing Management
Manufacturing Cell Design & Lean
Principles

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Aim :
This presentation aims on the study of how the cell manufacturing
designs 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 the
organization to become more lean.
Aim & Objective

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5 LeAN priNcipLes
Value - 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 the
customer’s rate of demand).
Perfection - strive for perfection by continually attempting to produce exactly
what the customer wants.

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Note : POUS – Point of Use storage
LeAN buiLdiNg bLOcks

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Cellular Flow Manufacturing is a method of
organizing manual and machine operations in
the most efficient combination to maximize
value-added content and minimize waste.
…is a lean manufacturing approach that
helps companies build a variety of products
for their customers with as little waste as
possible.
defiNitiON

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AdvANtAges/disAdvANtAges
Advantages:
• Reduce material handling
•Reduce tooling
•Reduced set-up times
•Reduced expediting
•Reduced in-process
inventory
•Improved human relations
Improved operator expertise
Disadvantages:
• Increased capital investment
• Lower M/C utilization
• Labor resistance (need for cross
training and flexibility)

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One Piece Flow
…is a condition that exists when
products move through a manufacturing
process one unit at a time, at a rate
determined by the needs of the
customer.

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Operating in a U-Shaped Cell
• Reduce travel distance
by arranging equipment
and workstations closer
together.
• Beginning of process is
closer to end of
process….minimizes the
travel distance for next
cycle
input output
Cell Lay-Out

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StepS of Cell DeSign
1. Document the current process
2. Define the product family and calculate
TAKT Time.
3. Balance the work to create flow between
work-stations that meets demand
4. Design the cell for ergonomics
5. Test and de-bug the cell design

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CaSe StUDY
Arvin Electronics Inc. was established in 1997 in
Europe. It was incorporated keeping a simple vision
“giving customer power of choice to choose from
varied range of quality products with good after-sales
support and service at affordable price”. The whole
idea was to give true value for money.
Cell design change at ARVIN Electronic Inc.

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Operation carried out by 6 operator
Bend Pipe and
trim inlet end
Heat and form
inlet end
Size and
inspect/test
flange and product
assembly
Weld flange
brackets and
assembly
Dimension check
and leak test

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Layout

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First pass work cell design… 3 people

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Second try – work cell design – 1 person

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RESULTS
BEFORE

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After ( first pass with 3 operator)

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RESULTS (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 )

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ConCLUSion
•The cell designing helps the organization to become more lean.
•The case study at Arvin electric clearly shows the various
benefits of implementing cellular manufacturing for the
organization as well as the customer.
•This type of layout helps in proper flow of material parts which
in 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.

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SUMMARY
• 5 Lean Principles
•Cellular manufacturing definition.
•Advantages and disadvantages.
•Steps involved in shifting from a traditional layout to
cellular layout
•Benefits of implementing cellular layout at Arvin
Electric Inc.

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