impementing cellular manufacturing
TRANSCRIPT
Implementing Cellular ManufacturingAt Pakistan Spring & Engineering Co. (Ltd.)
• To shorten lead times• To reduce inventory• To improve quality• To simplify Production scheduling• To reduce setup time
Why it is done?
Producing according to Takt Time (Line Balancing) Planning of layout must be feasible in order to cater
the cells made Pull system has to be integrated to the parts that are
to be arranged in a cell (Kanban) Individual Changeover times of machines must be
reduced to a minimum in order to benefit from cellular manufacturing
Prerequisites
Step 1
Data Collection
• Body C CD 70 cc• Seat Spring• Mouth Collar• Plate Baffle• Main Plate for Honda CG 125• Suzuki pickup steering spoke
Parts
Our Parts
Body C of CD 70 cc
Our Parts
Seat Spring of Honda CD 70 cc
Our Parts
Mouth Collar of Honda CD 70 cc
Our Parts
Plate Baffle of Honda CD 70 cc
Our Parts
Main Plate of Honda CG 125
Our Parts
Suzuki pickup steering spoke
Operations
Machine names with processes
Blanking on shearing press
Blanking on power press
1st Draw on Hydraulic Press
2nd Draw on Hydraulic Press
Cutting on Lathe
Facing on Lathe
Trimming on Power Press
Bending on Power Press
Punching on Pneumatic Press
Piercing on Power Press
Step 2
Sortation of process routings
A. Body C CD 70 cc 2-3-4-6-7 2000
B. Seat Spring 2-3-6-7 2500C. Mouth Collar 5-8-9 5000D. Plate Baffle 2-3-4-7 3000E. Main Plate for Honda CG 125 1-9-8 2500F. Suzuki pickup steering spoke 1-9-10-8 2500
Parts
Part Code Part Name Routing
Monthly Producti
on
OperationsOperation
Code Machine names with processes
1 Blanking on shearing press2 Blanking on power press
31st Draw on Hydraulic Press
4 2nd Draw on Hydraulic Press5 Cutting on Lathe6 Facing on Lathe7 Trimming on Power Press8 Bending on Power Press9 Punching on Pneumatic Press
10 Piercing on Power Press
Step 3
Process Flow Analysis (PFA) Chart/ Part-Machine incident
Matrix
Operations PartsA B C D E F
1 I I2 I I I 3 I I I 4 I I 5 I 6 I I 7 I I I I8 I I I9 I I I
10
Part machine Incident Matrix
Step 4
Cluster AnalysisPart I – Rank Order Clustering
OperationsParts
Decimal Equivalent Rank32 16 8 4 2 1
A B C D E F1 I I 3 9
2 I I I 52 1
3 I I I 52 2
4 I I 36 5
5 I 8 8
6 I I 48 4
7 I I I I 52 3
8 I I I 11 6
9 I I I 11 7
10 1 10
1st Iteration
1st Iteration
OperationsParts
32 16 8 4 2 1
A B C D E F2 I I I3 I I I7 I I I6 I I4 I I8 I I I9 I I I5 I1 I I
10 I
2nd IterationOperations Parts
A B C D E F2 I I I 512
3 I I I 256
7 I I I 128
6 I I 64
4 I I 32
8 I I I 16
9 I I I 8
5 I 4
1 I I 2
10 I 1
DecimalEquivalent 992 960 28 928 26 27
Rank 1 2 4 3 6 5
2nd Iteration
OperationsParts
Decimal Equivalent Rank32 16 8 4 2 1
A B D C F E
2 I I I 56 1
3 I I I 56 2
7 I I I 56 3
6 I I 48 4
4 I I 40 5
8 I I I 7 6
9 I I I 7 7
5 I 4 8
1 I I 3 9
10 I 2 10
Step 4
Cluster AnalysisHollier Method 2
From - To
To OperationCode Machine names with processes From
0 1 Blanking on shearing press 2500+2500
0 2 Blanking on power press 2000+2500+3000
2000+2500+3000 3 1st Draw on Hydraulic Press 2000+2500+3000
2000+3000 4 2nd Draw on Hydraulic Press 2000+3000
0 5 Cutting on Lathe 5000
2000+2500 6 Facing on Lathe 2000+2500
2000+3000+2500 7 Trimming on Power Press 0
5000+2500+2500 8 Bending on Power Press 5000
5000+2500+2500 9 Punching on Pneumatic Press 2500+2500
2500 10 Piercing on Power Press 2500
From - ToCluster 1
From
To
2 3 4 6 7 From sums From/To Ratio
2 0 7500 0 0 0 7500 ∞
3 0 0 5000 2500 0 7500 1
4 0 0 0 2000 3000 5000 1
6 0 0 0 0 4500 4500 1
7 0 0 0 0 0 0
To Sums 0 7500 5000 5000 7500 24500
Network Diagram
3 42 6 77500 7500
7500
2500
5000 2000
3000
4500
Performance Measures
Percentage in sequence moves = 19000/24500*100 = 77.5%
Percentage By-Passing Moves = 5500/24500*100 = 22.5 %
Percentage Back Tracking Moves = 0/24500*100 = 0 %
From-ToCluster 2
From
To
1 5 8 9 10 From sums
From/To Ratio
1 0 0 0 5000 0 7500 ∞
5 0 0 5000 0 0 7500 ∞
8 0 0 0 5000 0 5000 0.5
9 0 0 2500 0 2500 4500 0.5
10 0 0 2500 0 0 0 1
To Sums 0 0 10000 10000 2500 22500
Network Diagram
5 101 8 95000 0 5000
2500
0 2500
5000
5000
5000
5000
5000
2500
Performance Measures
Percentage in sequence moves = 7500/22500*100 = 33.33%
Percentage By-Passing Moves = 10000/22500*100= 44.44 %
Percentage Back Tracking Moves = 5000/22500*100 = 22.22 %
Conclusions
2 cells are made comprising of 5 machines
The cells are type II M (Group machine cell with manual handling)
For 1st cluster U shaped layout is suggested (As there are in sequence moves)
For 2nd cluster rectangular layout is suggested (As there are back track moves)
There is a drastic reduction in the “transportation” and “motion” waste