viernes, 21 de febrero de 2014

Cellular Manufacturing – Deployment Guide

Cellular Manufacturing , is a Lean Manufacturing approach for building a variety of products, delivering flexibility for Customers with minimum waste , variation and overburden.
Cellular Manufacturing consists of people, machines and work stations typically in U shape in processing sequence with flexible deployment of multi-skilled operators.

Elements of good Cellular Design.

       Design allows for One Piece Flow.
       Process steps are error proofed - Quality built into the process.
       Equipment and work stations are close together.
       Tools and material are presented at point of use based on frequency of use and ergonomics.
       Materials and tools are controlled visually making them very easy to identify
       All work areas are safe and ergonomic.
       Metrics and other key performance indicators are tracked and clearly seen
       Schedule is visual

Cellular Manufacturing - Where to deploy

Cellular Manufacturing eliminates waste by improving processes  as well as operations. A process is a continuous flow through which raw material is converted into finished products in a series of operation. In contrast, operation focuses on action in particular process step.

Deployment Guide.


Phase 1:

Map the Current Value Stream
       See 7 Flows
       See 7 Waste
       Identify customer demand
       Identify Kaizen burst


Use the 8 Standard work tool kit to baseline the sub processes and sub metrics.

(1)  Standard Work Sheet
(2)  Time Measurement sheet
(3)  Spaghetti Chart
(4)  Value Added Ratio
(5)  Standard Work Combination Sheet
(6)  Takt / Cycle Graph
(7)  Target Sheet
(8)  Capacity analysis chart


Analyze the process Product and Process communality to gets maximum benefit

PQ Analysis ( Product/Quantity) displays product mix as pareto chart

PR Analysis ( process/ route) Highlights processing similarities between different products
Helps identify product families that could be made in the cell,  using same sequence of machines.

Phase 2:

Break down the manufacturing process in the sequence the product is built. Arrange the work stations, people and machines sequentially in the way the product is built without de coupling the line.
Discuss and agree on new process map.


Ensure safety and good ergonomics
A process flow layout with the end point near the beginning point
Use dedicated hand tools and gravity to assist operator
Minimizes the waste of walking
Place machines very close for min WIP
Eliminate space where WIP accumulates


Revise the std work sheet for new process and new layout
Make new Standard Operating Procedures for the new process


Phase 3:

Create forcing functions for Continuous Improvement

Low Inventory manufacturing keep surfacing and amplifying problems for continuous improvement. Keep Single Piece Flow and Std WIP to amplify the impact of all other problems.

Some common problems
  1. Multi skilling
  2. Tools not available
  3. Machine Break down
  4. Change Over
  5. Defects
  6. Cycle Time


One person can run several machines/processes in a process sequence
Cross training gives flexibility and helps team take full responsibility for their process


Total productive maintenance (TPM)
A Company wide approach for reducing equipment related losses such as downtime, sped reduction and defects
Helps ensure equipment is  ready to run when needed.


Visual Management
A bulletin board displaying team activities and results in the manufacturing floor
Typical sections :
Company Vision
Mandatory Metrics
            WIP DOS
Continuous Improvement Metrics
Projects summary
Kaizen Burst for Future


1 comentario:

  1. It is really interesting for me to read this article. Thanks for it. I like such topics and everything connected to them.
    Lean Manufacturing definition
    Value stream mapping