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.

Fig.

Phase 1:

Map the Current Value Stream

•       See 7 Flows

•       See 7 Waste

•       Identify customer demand

•       Identify Kaizen burst

Fig.

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

Fig.

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.

Fig.

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

Fig.

Revise the std work sheet for new process and new layout

Make new Standard Operating Procedures for the new process

Fig.

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

Fig.

One person can run several machines/processes in a process sequence

Cross training gives flexibility and helps team take full responsibility for their process

Fig.

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.

Fig.

Visual Management

A bulletin board displaying team activities and results in the manufacturing floor

Typical sections :

Company Vision

Mandatory Metrics

            MultiSkill

            Yield

            WIP DOS

            Linearity

            MLT

Continuous Improvement Metrics

Projects summary

Kaizen Burst for Future

Fig.