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Cellular Manufacturing and Plant Layout

Cellular Manufacturing and Plant Layout. Lean Manufacturing Series. Disclaimer and Approved Use. Disclaimer This presentation is intended for use in training individuals within an organization. The handouts, tools, and presentations may be customized for each application.

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Cellular Manufacturing and Plant Layout

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  1. Cellular Manufacturingand Plant Layout Lean Manufacturing Series

  2. Disclaimer and Approved Use • Disclaimer • This presentation is intended for use in training individuals within an organization. The handouts, tools, and presentations may be customized for each application. • THE FILES AND PRESENTATIONS ARE DISTRIBUTED ON AN "AS IS" BASIS WITHOUT WARRANTIES OF ANY KIND, EITHER EXPRESSED OR IMPLIED. • Copyright • This presentation is created and copyrighted by LeanPresentations.com, owned and operated by Kanso Strategies LLC. • Approved Use • Each copy of this presentation can be used throughout a single Customer location, such as a manufacturing plant, or by a single Consultant or trainer when at multiple clients. Contact us for authorization to use this presentation at multiple locations. • The presentation may be customized to satisfy the customer’s application. • The presentation may not be re-sold or re-distributed without express written permission. • Current contact information can be found at: www.leanpresentations.com

  3. Outline • Fundamentals of layout • Process • Product • Fixed • Hybrid • Cellular Manufacturing • Characteristics • Implementing Cells • Part Families • Production Flow Analysis

  4. L G G L M Product Layout G D Part #1 M L A A Receiving Part #2 D M L Shipping Part #3

  5. Empowered Employees in Cells • Goals and tracking charts are maintained and posted. • Problems are solved through daily cell meetings and problem solving teams. • The inventory management system is a KANBAN Demand Pull instead of a work order/kit picking system. • Cells are responsible for planning, scheduling and expediting directly with vendors. • They establish and maintain a KANBAN system with the vendors.

  6. Factory Flow Analysis - Methodology • Study and map the existing flow system • Identify the dominant material flows between shops (or buildings) • Determine the Process Route Number (PRN) for each part • Analyze the part by PRN. • Combine closely associated processes at departments that complete most of the parts they make • If parts are observed to backtrack then such flows are eliminated by minor redeployment of equipment

  7. Group Analysis • The flows in each of the individual shops (identified by FFA) are analyzed. • Operation sequences of the parts that are being produced in a particular shop are analyzed to identify manufacturing cells. • Loads are calculated for each part family to obtain the equipment requirements for each cell

  8. PFA: Weakness • PFA is suitable mostly for small-sized applications, but it has difficulties coping with some large cell formation problems when the Machine-Part Matrix becomes more complex because of problem size

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