043_Cellular Layout & Part Family Identification

1
Cellular Layout & Part Family
Identification
1

4
Creation of Flow and Cell Design
● What is Flow?
Analogous to a river
Concerns both macro and micro process steps
Product must move smoothly from raw material to
finished product
Sequence of operations must follow each other
Produce in batches of one when possible
Flow Defined
The progressive achievement of tasks along the value
stream so that a product proceeds from design to
launch, order to delivery, and raw materials into the
hands of the customer with no stoppages, scrap, or back
flows.*
* Womack, J. P. and D. T. Jones, 1996, Lean Thinking, Simon & Schuster
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7
Evolution of Layouts
Over time process flows have continued to change in
order to maximize key metrics…
Types of Layouts:
• One to One
• Bird Cage
• Isolated Island
• Linear Layout
• U-Turn Cells
• Multiple U-Turn cells

10
Bird Cage Layouts
Bird Cage - One person assigned to One Type of equipment
DRILL
LATHE
LATHE
LATHE
LATHE

13
Isolated Island Pros & Cons
• Advantages
Cross-functional
resources
Productivity of person
typically increases
• Disadvantages
People are separate &
cannot help each other
Difficult to respond to
small changes in
demands
Overall productivity is
not as positively
impacted
More training required

16
U-Turn Cells Layout
Start
End
● U-Turn Cell - People assigned to multiple types of
equipment. People and materials, move from station to
station.

19
Multiple U-Turn cells
● BIG ADVANTAGE ** The area becomes more
efficient, as fractional parts of a person can be
spread among all cells!
5 People
6 cells
Adjustments in required output can be easily done!!

22
Designing Cells
● Elements to be considered:
Manpower
Machines
Materials
Methods
Environment
● Need to answer these questions:
What equipment should go into the cell?
What items or processes should be produced in cells?
How should people operate the cell?
Where should materials be placed?

25
Cellular Design Roadmap
P-Q Analysis
-
500
1,000
1,500
2,000
2,500
3,000
B
2
0C6
C
1
0
B
3
C
30
D2
A
2
0
C
5
B
3
0D
1D
1
0
B
4
A
30
D
9
D
3
0
D
3
C
1
0B
3
A1
0
B
1
C
2
0C
7D
20
C8
B10
B
2
Volume
0%
20%
40%
60%
80%
100%
120%
Cummulative%
P-Q Analysis
-
500
1,000
1,500
2,000
2,500
3,000
B
2
0C6
C
1
0
B
3
C
30
D2
A
2
0
C
5
B
3
0D
1D
1
0
B
4
A
30
D
9
D
3
0
D
3
C
1
0B
3
A1
0
B
1
C
2
0C
7D
20
C8
B10
B
2
Volume
0%
20%
40%
60%
80%
100%
120%
Cummulative%
● Product Quantity Analysis – initially narrow down opportunities
based on volume
● Demand Segmentation – narrow down further and segment based
on volume and variability
● Decomposition Methods – group parts by physical characteristics
● Product/Process matrix – group parts and equipment into cells
1 2 3 4 8 5 6 7 9 10 11 12 14 13 15 16 17 18
Machines
PartC
PartM
PartA
PartR
PartE
PartL
PartT
PartF
PartQ
PartB
PartK
PartP
PartS
PartG
PartD
PartH
PartN
PartJ
Power Weight Rank
1 102-B 1 1 1 1 2 282 1
2 107-G 1 1 1 1 4 284 2
3 108-H 1 1 1 1 8 284 2
4 103-C 1 1 1 1 1 16 17120 4
5 106-F 1 1 1 1 1 32 23680 5
6 105-E 1 1 1 1 1 1 64 23744 6
7 101-A 1 1 1 1 1 128 319744 7
8 104-D 1 1 1 1 1 1 1 1 1 256 491008 8
9 109-J 1 1 1 1 512 491520 9
10 110-K 1 1 1 1 1024 491520 9
Power
2
4
8
16
256
32
64
128
512
1024
2048
4096
16384
8192
32768
65536
131072
262144
Weight
2
12
14
14
142
16
80
112
272
352
352
352
496
384
1664
1792
1792
1920Rank
1
2
3
3
8
5
6
7
9
10
10
10
14
13
15
16
16
18
Analyze Identify Implement

28
Cell Design Considerations
● Tools and Materials Should Be:
Placed for the operator’s convenience
Placed closely to and in front of the operator
Kept in designated place
● Work Station Design
Bench height designed for operator and nature of
work
Lighting best suited for the operator and the work
Minimum travel distance between operations
Standing preferred for flexibility
● Material Movement:
Avoid vertical transfers
Move objects horizontally
Use gravity to move objects
● Address Ergonomic Issues
Layout and Equipment
All oils, water,
electrical, air, gas, etc.
should be
plumbed/piped to the
point of use

31
Visual Layout - Work Cells
Design of the cell should be “Visual”
Ask:
Can a person see everything from one point?
Can they quickly observe abnormalities?
Is the work area designed for visual systems?
Are areas identified where materials are stored?
Where is raw material stored? - How much?
Look for opportunities to add Visual indicators wherever
possible.
Lines on floors
Color coding containers or folders
Shadow boards or outlined areas for locating equipment

34
Keys to Success
● Include process personnel on the Design Team.
● Have Cross Functional representation on the Team.
● Be creative to overcome industry/company specific
challenges.
● Address sources of process variation - time and quality
variation.
● Design flexibility into the process.
● Keep things simple!
● Apply only where it is appropriate.
● Break old paradigms.
● Challenge, Challenge, Challenge, question everything - find
“root causes” for “why it must be that way”.

37
Cellular Design Roadmap
P-Q Analysis
-
500
1,000
1,500
2,000
2,500
3,000
B
2
0C6
C
1
0
B
3
C
30
D2
A
2
0
C
5
B
3
0D
1D
1
0
B
4
A
30
D
9
D
3
0
D
3
C
1
0B
3
A1
0
B
1
C
2
0C
7D
20
C8
B10
B
2
Volume
0%
20%
40%
60%
80%
100%
120%
Cummulative%
P-Q Analysis
-
500
1,000
1,500
2,000
2,500
3,000
B
2
0C6
C
1
0
B
3
C
30
D2
A
2
0
C
5
B
3
0D
1D
1
0
B
4
A
30
D
9
D
3
0
D
3
C
1
0B
3
A1
0
B
1
C
2
0C
7D
20
C8
B10
B
2
Volume
0%
20%
40%
60%
80%
100%
120%
Cummulative%
● Product Quantity Analysis – initially narrow down opportunities
based on volume
● Demand Segmentation – narrow down further and segment based
on volume and variability
● Decomposition Methods – group parts by physical characteristics
● Product/Process matrix – group parts and equipment into cells
1 2 3 4 8 5 6 7 9 10 11 12 14 13 15 16 17 18
Machines
PartC
PartM
PartA
PartR
PartE
PartL
PartT
PartF
PartQ
PartB
PartK
PartP
PartS
PartG
PartD
PartH
PartN
PartJ
Power Weight Rank
1 102-B 1 1 1 1 2 282 1
2 107-G 1 1 1 1 4 284 2
3 108-H 1 1 1 1 8 284 2
4 103-C 1 1 1 1 1 16 17120 4
5 106-F 1 1 1 1 1 32 23680 5
6 105-E 1 1 1 1 1 1 64 23744 6
7 101-A 1 1 1 1 1 128 319744 7
8 104-D 1 1 1 1 1 1 1 1 1 256 491008 8
9 109-J 1 1 1 1 512 491520 9
10 110-K 1 1 1 1 1024 491520 9
Power
2
4
8
16
256
32
64
128
512
1024
2048
4096
16384
8192
32768
65536
131072
262144
Weight
2
12
14
14
142
16
80
112
272
352
352
352
496
384
1664
1792
1792
1920Rank
1
2
3
3
8
5
6
7
9
10
10
10
14
13
15
16
16
18
Analyze Identify Implement

40
1. Visual Method
2. Coding Method
Visual Method
Other Clustering Methods
Before Visual Classification
PF - 1
PF - 3 PF - 4
PF - 2
After Visual Classification

43
• The Product/Process Matrix leads to grouping parts into
part families (PF) and machines into machine cells (MC)
• The result of this grouping is implemented as physical
cellular machine layout
Product/Process Matrix
1 2 3 4 8 5 6 7 9 10 11 12 14 13 15 16 17 18
Machines
PartC
PartM
PartA
PartR
PartE
PartL
PartT
PartF
PartQ
PartB
PartK
PartP
PartS
PartG
PartD
PartH
PartN
PartJ
Power Weight Rank
1 102-B 1 1 1 1 2 282 1
2 107-G 1 1 1 1 4 284 2
3 108-H 1 1 1 1 8 284 2
4 103-C 1 1 1 1 1 16 17120 4
5 106-F 1 1 1 1 1 32 23680 5
6 105-E 1 1 1 1 1 1 64 23744 6
7 101-A 1 1 1 1 1 128 319744 7
8 104-D 1 1 1 1 1 1 1 1 1 256 491008 8
9 109-J 1 1 1 1 512 491520 9
10 110-K 1 1 1 1 1024 491520 9
Power
2
4
8
16
256
32
64
128
512
1024
2048
4096
16384
8192
32768
65536
131072
262144
Weight
2
12
14
14
142
16
80
112
272
352
352
352
496
384
1664
1792
1792
1920
Rank
1
2
3
3
8
5
6
7
9
10
10
10
14
13
15
16
16
18

46
Decomposition
Algorithm

49
2. Select Row # 1 In The Matrix and draw a
horizontal line (Use Green line)
Parts
Machi
nes
Part#1 Part#2 Part#3 Part#4 Part#5 Part#6 Part#7 Part#8
Machine
#1
1 1 1
Machine
#2
1 1
Machine
#3
1 1
Machine
#4
1 1
Machine
#5
1 1 1
Machine
#6
1
Machine
#7
1 1 1 1

52
5. Repeat Steps: 7.3 & 7.4 Until No More Crossed “1”
Crossed Once. All Crossed Twice Form Potential Projects
That May or May Not Decomposed Further Depending on
the Constraints.
Parts
Machi
nes
DP#1 DP#2 DP#3 DP#4 DP#5 DP#6 DP#7 DP#8
Machine
#1
1 1 1
Machine
#2
1 1
Machine
#3
1 1
Machine
#4
1 1
Machine
#5
1 1 1
Machine
#6
1
Machine
#7
1 1 1 1

55
7.b. Repeat The Process For Submatrix 1.2.
Parts
Mach
ines
Part#1 Part#4 Part#6 Part#7
Machin
e#2
1 1
Machin
e#3
1 1
Machin
e#4
1 1
Machin
e#6
1
+=
Parts
Mach
ines
Part#1 Part#6
Machin
e#2
1 1
Machin
e#4
1 1
Parts
Mach
ines
Part#4 Part#7
Machin
e#3
1 1
Machin
e#6
1
Table 1.2.1:
Crossed
Matrix
Table 1.2.2:
Left-Over
Matrix

58
Tools
None specific to this module

1
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043_Cellular Layout & Part Family Identification

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043_Cellular Layout & Part Family Identification