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Work Cell Integration: Working with Existing Facilities. Working Conditions and Practices: constraints/barriers for true work cell integration. Cellular Manufacturing.
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Work Cell Integration: Working with Existing Facilities Working Conditions and Practices: constraints/barriers for true work cell integration
Cellular Manufacturing • “A manufacturing cell is a small unit, consisting of several workstations. A workstation usually contains either one machine or several machines with each machine performing a different operation on the part” (Kalpakjian & Schmid, 2006). • Cells are made up of people, machines, devices, and support systems.
Integration Revisited • Integrate = “to make or become whole or complete” (Websters, 1984) • Integrate = “to form, coordinate, or blend into a functioning or unified whole : unite” (“Webster’s Ninth”, 1989, p. 628) • Integration requires organization, visual control, cleanliness, safety, and sustained efforts to maintain positive working conditions and control over production output
Work Cell Integration:Constraints/Barriers • People attitudes – complacency, apathy, laziness – unwillingness to cooperate (company culture) • Presence of hazardous working conditions – sanitation level, temperature levels, air quality levels • Organization of the work area (cell/line) – Design of working area • Space available for operations – How space is utilized
Companies Collect and Store • Processes not in use • Tools not in use • Material not in use • Chemicals not in use • Parts/products not in use • Equipment not in use • Scrap / Material-Related Waste
Processes Not In Use • Consume Floor Space – become obstructing • Collect dust / filth • Require moving and removing • Can require significant maintenance to become operational $$$ • Can require significant learning/retraining time to become operational $$$
Cells / Lines Often Lack Organization • Tools become lost in drawers, bins, cabinets (do not have a place)= lack of visual control • Chemicals are often stored in unsafe manners – containers often lack labeling • Drawers and cabinets are magnets for clutter, personal equipment, unused tools, unused parts/material, etc. • Ability to add value in work area becomes severely degraded
Work Areas Conditions May Be Unsanitary • Machines/equipment may be filthy – gages, instructions may be difficulty or impossible to read – safety mechanisms may not be visible or accessible • Floor surfaces may be slippery • Electrical Hazards may exist • Food or drink may be allowed in the work areas becoming a health hazard
Work Area Conditions • Processes, tools, material, chemicals, parts/products, equipment, and scrap not in use can hinder production and production improvement efforts. • Personnel can become used to unsafe, unclean, and unorganized work areas – this can make them unproductive • Cells / lines may fail to integrate because of work area conditions
Integration Barriers • Without organization, visual control, cleanliness, safety, and sustained efforts, cell operations fail to work together (to unite, to integrate) in an efficient manner • Companies can adopt sloppy practices that can affect performance, perception, and safety. • Companies must adopt a culture that minimizes non-value-added (wasteful) practices to increase control over production output.
