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Cellular Manufacturing is an application of group technology in which dissimilar machines or processes have been aggregated into cells, each of which is dedicated to the production of a part or product family or a limited group of families.
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A manufacturing cell is a cluster of machines or processes located in close proximity and dedicated to the manufacturing of a family of parts.
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supporting fixtures and tooling. One or more part families with one basic type of process (such as milling) can be processed.
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Part size, shape, weight, and other physical attributes: Determines the size and type of material handling and processing equipment that can be used.
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Decide on the scope (population of parts to be analyzed) collect the necessary data (part number, machine routing, lot size, annual production rate).
Step 2: Sorting of Process Routings:
Arrange the parts into packs (group of parts with identical process routings).
Step 4: Analysis:
Most subjective and most difficult step in PFA. Rearrange the data on the PFA chart to bring the packs with similar routings together to determine the logical machine cells.
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Step 4: Continue preceding steps until there is no change in the position of each element in each row and column
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Single-Linkage Cluster Analysis (SLCA) Algorithm-I Similarity coefficients between machines are used to construct a tree called dendrogram. A dendrogram is a pictorial representation of bonds of similarity between machines as measured by the similarity coefficients. Similarity coefficient between two machines is the ratio of the number of parts visiting both machines and the number of parts visiting one of the two machines. Xijk=operation on part k performed both on machine i and j, Yik=operation on part k performed on machine i, Zjk= operation on part k performed on machine j.
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Single-Linkage Cluster Analysis (SLCA) Algorithm-II Step1: Compute similarity coefficients for all possible pairs of machines. Step 2: Select the two most similar machines to form the first machine cell. Step 3: Lower the similarity level (threshold) and form new machine cells by including all the machines with similarity coefficients not less than the threshold value. Step 4: Continue step 3 until all the machines are grouped into a single cell.
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3 1
5 1
1 1 1
1 1 1 1 1 1
Part Number
B. WT. E 24 23 22 21 20 24+23 = 24 1 1 1 1 1 1 1 1 1 1 24=16 3 2 3 4 1 1 1 5 6 1
D. Equiv Rank
Machine ID
C D B A
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Part Number
1 B Wt: E 25 1 4 24 1 6 23 1 3 22 2 21 5 20
D. Eqv
Rank
Machine ID
D B A
3 4 5
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Typical Objectives of Cellular Manufacturing: To shorten manufacturing lead times by reducing set up, work handling ,waiting times and batch sizes. To reduce work-in-process inventory-smaller batch sizes and shorter lead times reduce work-in-process. To improve quality- This reduces process variations. To simplify production scheduling- This reduces the complexity of product on scheduling. To reduce set up times- This is accomplished by using group tooling that have been designed to process the part family.
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Engineering Design
Reduction in new parts design Reduction of drafting effort in new shop drawings Reduction of number of similar parts, easy retrieval of similar functional parts, and identification of substitute parts
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Reduction in number of machining operations and numerical control (NC) programming time
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