Manufacturing cell design

M. S. Ramaiah School of Advanced Studies 1

By

Sreejesh SP – BUB0412005

21 st April 2013

Module: Lean Operation and Management of lean organization

Module Leader: Mr. Sandeep .N

M. Sc. ( Engg.) in Engineering and Manufacturing Management

Manufacturing Cell Design & Lean Principles


Aim : This presentation aims on the study of how the cell manufacturing designs helps to implement the lean culture.

Objective :The main objectives of this presentation are•Understanding the principles of lean.• Knowing the importance of cellular manufacturing in an industry.•Also to check how the implementation of cellular layout can help the organization to become more lean.

Aim & Objective


5 LEAN principles

Value - specify what creates value from the customer’s perspective.

The value stream – identify all the steps along the process chain.

Flow - make the value process flow.

Pull - make only what is needed by the customer (short term response to the

customer’s rate of demand).

Perfection - strive for perfection by continually attempting to produce exactly

what the customer wants.


Note : POUS – Point of Use storage

Lean Building Blocks


Cellular Flow Manufacturing is a method of organizing manual and machine operations in the most efficient combination to maximize value-added content and minimize waste.

…is a lean manufacturing approach that helps companies build a variety of products for their customers with as little waste as possible.

Definition


Advantages/Disadvantages

Advantages:

• Reduce material handling

•Reduce tooling

•Reduced set-up times

•Reduced expediting

•Reduced in-process

inventory

•Improved human relations

Improved operator expertise

Disadvantages:

• Increased capital investment

• Lower M/C utilization

• Labor resistance (need for cross

training and flexibility)


One Piece Flow

…is a condition that exists when products move through a manufacturing process one unit at a time, at a rate determined by the needs of the customer.


Operating in a U-Shaped Cell

• Reduce travel distance by arranging equipment and workstations closer together.

• Beginning of process is closer to end of process….minimizes the travel distance for next cycle

input output

Cell Lay-Out


Steps of Cell Design

1. Document the current process2. Define the product family and calculate

TAKT Time.3. Balance the work to create flow between

work-stations that meets demand4. Design the cell for ergonomics 5. Test and de-bug the cell design


Case STUDY

Arvin Electronics Inc. was established in 1997 in Europe. It was incorporated keeping a simple vision “giving customer power of choice to choose from varied range of quality products with good after-sales support and service at affordable price”. The whole idea was to give true value for money.

Cell design change at ARVIN Electronic Inc.


Operation carried out by 6 operator

Bend Pipe and trim inlet end

Heat and form inlet end

Size and inspect/test

flange and product assembly

Weld flange brackets and assembly

Dimension check and leak test


Layout


First pass work cell design… 3 people


Second try – work cell design – 1 person


RESULTSBEFORE


After ( first pass with 3 operator)


RESULTS (contd.)

Floor space reduction nearly 50%

Customer rejects reduced 95%

Scrap reduced 62%

Work in process reduced 91%

Changeover time reduced by 78%

Labor cost as % of sales reduced 41%

(Documented savings )

(ref:www.innomet.ee/innomet/ERPKoolitus/1.JIT_Solution.ppt )


Conclusion

•The cell designing helps the organization to become more lean.

•The case study at Arvin electric clearly shows the various

benefits of implementing cellular manufacturing for the

organization as well as the customer.

•This type of layout helps in proper flow of material parts which

in turn reduces the inventory.

•All the 5 principle of lean i.e. Value, The value stream, Flow,

Pull and Perfection is followed by modifying the cell layout.


SUMMARY

• 5 Lean Principles

•Cellular manufacturing definition.

•Advantages and disadvantages.

•Steps involved in shifting from a traditional layout to

cellular layout

•Benefits of implementing cellular layout at Arvin

Electric Inc.



Technology

Manufacturing cell design