cellular manufacturing
DESCRIPTION
WCMTRANSCRIPT
Cellular Manufacturing
Lean Manufacturing , Cell Design
Systematic approach of identifying & eliminating waste. Improved Quality, Higher throughput,
Better efficiency. To do more & more with less & less – Less
men, less equipment, less time, less space, less material.
Lean Manufacturing , Cell Design
Traditional System of Manufacturing –
- Production based on demand forecast.
- Storage of Material & Components till required
for processing.
- Actual production with stress on large batches.
- Storage of components required for assembly.
- Assembly, final inspection & packaging.
- Storage of finished goods in company Godowns;
Zonal depots ; retail outlets.
Lean Manufacturing , Cell Design
Weakness of traditional system -
- Risk related to forecasts. - Long overall business cycle.
- Buffers in various stages leading to slackness in
the system.
- Encourages departmental focus.
Lean Manufacturing , Cell Design
Wastes associated with traditional system –
- Waste due to waiting time of men, machine, material
- Waste due to un-necessary movement of material.
- Waste due to In-process inventory.
- Waste due to producing defective goods.
Lean Manufacturing , Cell Design
Lean manufacturing system –
- Produce against order – As per Takt time- JIT receipt of material
- Pull system
Lean Manufacturing , Cell Design
Key Principals –
- Minimize Material handling, Gravity feed, Handle
products once only.
- Minimize distance – Create cells, Avoid walking,
carrying.
- Minimize strain – Ergonomic design, Hydro
pneumatic clamping.
Lean Manufacturing , Cell Design
Key Principals –
- Minimize clutter – parts, tools, gauges, products at
designated places, 5S.
- Minimize storage.
- Maximize utilization of – People, space, equipment.
- Maximize flexibility : Personal – Multi skilling
Equipment – SMED.
Lean Manufacturing , Cell Design
Key Principals –
- Maximize visibility – Quality spot problem.
- Maximize communication –
Sunrise meetings,
Daily plan Vs achieved.
The Component (Ball Pin)
Cell Lay out
BTBMSPM
Drilling Thread Rolling GatewayOUT
CNC TurningGateway
IN
Ball Pin Cell
M/c No
M/c Operation
Cycle time in Seconds
Unload load
Inspect Walk M/c auto
1 CNC Late
Profile turning
4 4 4 to m/c 2 25
2 BTBM (SPM)
Ball Turning
6 - 4 to m/c 3 14
3 Bench drill
Centering 4 - 4 to m/c 4 6
4 Thread Rolling
Threading 3 - 4 to m/c 1 7
Socket CellP
illar
dri
ll
CNC Lathe Bench drill CNC Lathe Thread Rolling
Pil
lar
Dri
ll
Socket Cell
M/c No
M/c Operation
Cycle time in SecondsUnload Load
Inspect Walk M/c Auto
1 Pillar drill Rough Drill 6 - 4 to m/c 2 20
2 CNC Lathe Socket turning 4 4 4 to m/c 3 35
3 Bench drill Centering 3 - 6 to m/c 1 6
4 CNC Lathe Stem turning 6 4 4 tom/c 5 32
5 Thread Rolling
Threading 3 - 4 to m/c 6 8
6 Pillar drill Back opening 4 - 6 to m/c 4 10