Ebook Download Cellular Manufacturing: One-Piece Flow for Workteams Ebook, Epub

CELLULAR MANUFACTURING: ONE-PIECE FLOW FOR WORKTEAMS PDF, EPUB, EBOOK

Browse All Regulations. I'm looking for support for Other Glossary Terms. The concept of cellular manufacturing is an important component for both JIT manufacturing and Lean organizations. It is a process used to support and facilitate one-piece flow in production by having equipment, workstations, and cells arranged in order of processes to produce a single or very small batch of products. Traditionally in manufacturing, similar machines are placed near each other with parts being processed and moved between different departments in large batches. This can lead to unexpected breakdowns, piled up inventory, and unnecessary motion, resulting in valuable resources waste. On the other hand, a cellular layout operates on the pull system with products being made only as they are demanded and in very small batches. The production line is comprised of multiple cells sequenced in the order of operations and the work cells themselves are then placed near each other to save space and reduce unnecessary movement while streamlining the flow. For example, the department receiving the raw materials inventory can be placed at one end of the facility and the first value-added process is in a work cell right next to the department. From there, products move from cell to cell, with one part of the manufacturing process being completed within each cell. The finished product ends up at the shipping department, which would be opposite to the receiving department in a U-shaped layout. Be the first to like this. No Downloads. Views Total views. Actions Shares. No notes for slide. Cellular manufacturing one piece flow for workteams 1. You just clipped your first slide! Clipping is a handy way to collect important slides you want to go back to later. Now customize the name of a clipboard to store your clips. Visibility Others can see my Clipboard. Cancel Save. Tell us about it below…. Your email address will not be published. Save my name, email, and website in this browser for the next time I comment. This site uses Akismet to reduce spam. Learn how your comment data is processed. What is Lean? What is Heijunka? What is Andon cord? What is Poka Yoke? What is Kaizen? What is One Piece Flow? What is Kanban? What is Pull versus Push? What is Just in Time? What is SMED? What is a Toyota A3 Report? What is 5S? What is Shop Floor Management? Cellular manufacturing one piece flow for workteams by Standards Media - Issuu

There are various commonly used designs that can be appropriate in different circumstances, and they mostly determine the shape of the manufacturing chain. The key benefit of a properly designed cell is that it reduces floor space, reduces delays and hand-offs within the value stream, and improves communication between process steps. Implementing cellular manufacturing begins by splitting the production process down into sensible steps. Note that this does not mean breaking it down into the most fundamental, basic steps, but rather to organize the various steps into sensible groups according to the complexity of the tasks involved, and the need for communication between separate units. Ideally, a Value Stream Map should be created, showing all the steps required to create value for the customer, based on the product or service they are requesting from your company. If the sub components are not supplied, but manufactured within the facility, they might be incorporated into the cell, or they could be assigned to their own cell. It depends how much of the sub component is used in other cells within the facility. If it only goes to the one final product, then it should be included in the cell. Choosing the right layout is just as important as splitting the cells correctly in the first place. There are multiple different commonly used layouts to choose from, and with some creativity, you may even be able to come up with your own. The important thing is that you weigh the benefits and disadvantages of each common layout according to your own situation. Remember to regularly revise the design of your cellular manufacturing plant, and think about alternatives that can improve the production flow. After all, one of the core concepts of lean manufacturing is constant improvement, and cellular manufacturing is no exception. In a positive way, cross training will allow them to take on more work. On the negative side, you might be replacing experienced employees, and less can be done by each employee. The shape will need to change to reflect the current experience level. Cellular manufacturing is a natural result of the desire to think analytically and break down processes into simple components that can be easily analyzed, exchanged and reorganized. Have you tried to create a cell design that was unique or different than the models suggested above? Tell us about it below…. Your email address will not be published. Save my name, email, and website in this browser for the next time I comment. This site uses Akismet to reduce spam. Learn how your comment data is processed. What is Lean? What is Heijunka? What is Andon cord? What is Poka Yoke? What is Kaizen? It is for this reason that the one-piece-flow cell has been called "the ultimate in lean production. Cellular manufacturing is derivative of principles of group technology, which were proposed by Flanders in [2] and adopted in Russia by Mitrofanov in whose book [3] was translated into English in Burbidge actively promoted group technology in the s. By cells had come to be treated as foundation practices in JIT manufacturing, so much so that Harmon and Peterson, in their book, Reinventing the Factory , included a section entitled, "Cell: Fundamental Factory of the Future". Cells are created in a workplace to facilitate flow. This is accomplished by bringing together operations or machines or people involved in a processing sequence of a products natural flow and grouping them close to one another, distinct from other groups. This grouping is called a cell. These cells are used to improve many factors in a manufacturing setting by allowing one-piece flow to occur. First, the pieces would be moved from storage to the cell, where they would be welded together, then polished, then coated, and finally packaged. Some common formats of single cells are: the U-shape good for communication and quick movement of workers , the straight line, or the L-shape. The number of workers inside these formations depend on current demand and can be modulated to increase or decrease production. For example, if a cell is normally occupied by two workers and demand is doubled, four workers should be placed in the cell. Similarly, if demand halves, one worker will occupy the cell. Since cells have a variety of differing equipment, it is therefore a requirement that any employee is skilled at multiple processes. While there exist many advantages to forming cells, there are some obvious benefits. It is quickly evident from observation of cells where inefficiencies lie, such as when an employee is too busy or relatively inactive. When formation of a cell would be too difficult, a simple principle is applied in order to improve efficiencies and flow, that is, to perform processes in a specific location and gather materials to that point at a rate dictated by an average of customer demand this rate is called the takt time. This is referred to as the Pacemaker Process. Despite the advantages of designing for one-piece-flow, the formation of a cell must be carefully considered before implementation. Use of costly and complex equipment that tends to break down can cause massive delays in the production and will ruin output until they can be brought back online. Manufacturing cells [closely locate] people and equipment required for processing families of like products. After reorganization, families of similar parts are produced together within the physical confines of cells that house most or all of the required resources, Furthermore, cell operators can be cross-trained in several machines, engage in job rotation, and assume responsibilities for tasks [that] previously belonged to supervisors and support staff [including] activities such as planning and scheduling, quality control, trouble-shooting, parts ordering, interfacing with customers and suppliers, and record-keeping. The short travel distances within cells serve to quicken the flows. Moreover, the compactness of a cell minimizes space that might allow build-ups of inventory between cell stations. To formalize that advantage, cells often have designed-in rules or physical devices that limit the amount of inventory between stations. Discussion and illustrations of cells in combinations with kanban are found in [12] The simplest form, kanban squares, are marked areas on floors or tables between work stations. The rule, applied to the producing station: "If all squares are full, stop. If not, fill them up. An office cell applies the same ideas: clusters of broadly trained cell-team members that, in concert, quickly handle all of the processing for a family of services or customers. A virtual cell is a variation in which all cell resources are not brought together in a physical space. In a virtual cell, as in the standard model, team members and their equipment are dedicated to a family of products or services. Although people and equipment are physically dispersed, as in a job shop, their narrow product focus aims for and achieves quick throughput, with all its advantages, just as if the equipment were moved into a cellular cluster. A simple but rather complete description of cell implementation comes from a booklet of 96 pages by Kone Corp. Excerpts follow:. In April six cells, identified by different colors, were established All devices manufactured in cells are identified by the cell's color, and all feed-back from quality control is directed straight to the workers of the cell concerned The second step, in summer, , was to "cellularize" manufacture of the analyzer subassemblies [that are] needed in the analyzer cells, and to test them if necessary. Production of the five sub-assembly cells consists exclusively of certain analyzer sub-units. The parts and materials are located in the cells Material control between the cells is based on the pull system and actual demand. In the analyzer cells there is a buffer consisting of two pieces for each roughly 25 different sub-unit. When one piece is taken into assembly, a new one is ordered from the corresponding unit-cell. The order is made [using] a magnetic [kanban] button, which identifies the ordering cell by color , unit by code , and order date When the manufacturing cell has completed the order, the unit is taken with the [kanban] button to its place on the ordering cell shelf. Orders from the unit cells to the sub-cells are based on the same principle. The only difference is that the buffer size is six sub- units. This [procedure] was implemented in August, In order to implement cellular manufacturing, a number of steps must be performed. First, the parts to be made must be grouped by similarity in design or manufacturing requirements into families. Clustering of machines and parts is one of the most popular production flow analysis methods. There are also a number of mathematical models and algorithms to aid in planning a cellular manufacturing center, which take into account a variety of important variables such as, "multiple plant locations, multi-market allocations with production planning and various part mix. The key to creating flow is continuous improvement to production processes. Upon implementation of cellular manufacturing, management commonly "encounters strong resistance from production workers". In this process. It is also difficult to fight the desire to have some inventory on hand. It is tempting, since it would be easier to recover from an employee suddenly having to take sick leave. Unfortunately, in cellular manufacturing, it is important to remember the main tenants: "You sink or swim together as a unit" and that "Inventory hides problems and inefficiencies. Another common set of problems stems from the need to transfer materials between operations. These problems include, "exceptional elements, number of voids, machine distances, bottleneck machines and parts, machine location and relocation, part routing, cell load variation, inter and intracellular material transferring, cell reconfiguring, dynamic part demands, and operation and completion times. Cellular manufacturing brings scattered processes together to form short, focused paths in concentrated physical space. So constructed, by logic a cell reduces flow time, flow distance, floor space, inventory, handling, scheduling transactions, and scrap and rework the latter because of quick discovery of nonconformities. Moreover, cells lead to simplified, higher validity costing, since the costs of producing items are contained within the cell rather than scattered in distance and the passage of reporting time. Cellular manufacturing facilitates both production and quality control. The segmentation of the production process allows problems to be easily located and it is more clear which parts are affected by the problem. There are also a number of benefits for employees working in cellular manufacturing. Cellular manufacturing one piece flow for workteams

Engineers need to dedicate a good amount of time to their books and grasp topics on how to help and maintain a proper functioning of a machine. These books gives theoretical knowledge on the procedure of manufacturing, but one should always learn the practical side where these theoretical conventions are applicable. Kaizen For The Shopfloor. Search this site. Cellular Manufacturing and Engineering. Hand Books on the process of functioning a Manufacturing Unit. Procedures to identify wastes on shop floors. The use of Kaizen and the procedure for Maintenance in a manufacturing unit. Each chapter includes an overview and a summary to reinforce concepts, as well as reflection questions, which can be used to encourage group discussions. All Rights Reserved. We began our journey by marketing traditional technical and management books. In 7 years of working we have realized from our Customers the need of International Standards. With our continuous efforts of pursuing the needs of International standards , fair and smooth dealing, many of the International agencies given us the opportunity of direct dealing of their published standards. View All Standards. View All Publishers. Our Publications. The 5S Improvement Handbook. View All Our Publications. Categories About Us. Price: Rs 2,

ONE PIECE FLOW versus BATCH PRODUCTION - Lean Manufacturing - Video Dailymotion Products Sold on our sister site CrystalGraphics. Title: Lean Manufacturing. Tags: lean manufacturing. Latest Highest Rated. The focus is the path of the materials as they are transformed into something to sell. Manufacturing processes have four basic types of steps or phases Transformation assembly, machining Inspection comparison to standard Transport change of location Storage waiting period Only Transformation adds value! In contrast to process, which focuses on flow, an operation focuses on action. An operation is any action performed by workers or machines on the materials. Operational improvements focus on how specific actions are carried out, and include studying the motions required for a specific action. Cellular manufacturing also helps you as a company employee By straightening the companys competitiveness, it helps support job security Makes daily production work go smoother by Removing clutter of excess WIP inventory Reducing transport and unnecessary handling Reducing walking required to complete processes Addressing causes of defects and machine problems that cause delays You may have to learn a process sequence you have not done before. Raise your skill and flexibility, and may change how you think about your role in the company Learning about and participating in a JIT transformation ultimately will make you more employable! A cell may be run by one person or by several people working together Depending on the size of the cell, cycle times, or production volume Flexibility to change how people work together in a cell comes from cross-training 20 Cross-Training for Maximum Flexibility Cross-training enables employees to perform different functions within a process Lets teams take full responsibility for their processes. Whether your application is business, how-to, education, medicine, school, church, sales, marketing, online training or just for fun, PowerShow. And, best of all, most of its cool features are free and easy to use. You can use PowerShow. Or use it to find and download high-quality how-to PowerPoint ppt presentations with illustrated or animated slides that will teach you how to do something new, also for free. Or use it to upload your own PowerPoint slides so you can share them with your teachers, class, students, bosses, employees, customers, potential investors or the world. That's all free as well! For a small fee you can get the industry's best online privacy or publicly promote your presentations and slide shows with top rankings. But aside from that it's free. We'll even convert your presentations and slide shows into the universal Flash format with all their original multimedia glory, including animation, 2D and 3D transition effects, embedded music or other audio, or even video embedded in slides. All for free. Most of the presentations and slideshows on PowerShow. You can choose whether to allow people to download your original PowerPoint presentations and photo slideshows for a fee or free or not at all. Check out PowerShow. There is truly something for everyone! Related More from user. Promoted Presentations. World's Best PowerPoint Templates - CrystalGraphics offers more PowerPoint templates than anyone else in the world, with over 4 million to choose from. They'll give your presentations a professional, memorable appearance - the kind of sophisticated look that today's audiences expect. Boasting an impressive range of designs, they will support your presentations with inspiring background photos or videos that support your themes, set the right mood, enhance your credibility and inspire your audiences. SlideShare Explore Search You. Submit Search. Home Explore. Successfully reported this slideshow. We use your LinkedIn profile and activity data to personalize ads and to show you more relevant ads. You can change your ad preferences anytime. Upcoming SlideShare. Like this document? Why not share! Embed Size px. Start on. Show related SlideShares at end. WordPress Shortcode. Published in: Education. Full Name Comment goes here. Are you sure you want to Yes No.

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