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Cycle time reduction in cellular manufacture systems


TECHNICAL PAPER

TP07PUB106
Cycle Time Reduction in Cellular Manufacturing Systems
author(s)
T. PAGE G. THORSTEINSSON
Loughborough University Loughborough, Leice

stershire, England

abstract
This paper presents a cellular manufacturing classification system in the context of cycle time optimization. This work provides formulae for the calculation of manufacturing cycle time for the purpose of effective implementation and management of operations. Furthermore, it considers operational issues for such effective implementation.

terms
Cellular Manufacturing Computer-Integrated Manufacturing Cycle Time Reduction

2007

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SME TECHNICAL PAPERS This Technical Paper may not be reproduced in whole or in part in any form without the express written permission of the Society of Manufacturing Engineers. By publishing this paper, SME neither endorses any product, service or information discussed herein, nor offers any technical advice. SME specifically disclaims any warranty of reliability or safety of any of the information contained herein.

Cycle Time Reduction in Cellular Manufacturing Systems
T. Page & G. Thorsteinsson, Department of Design & Technology, Loughborough University, UK
Abstract: This paper presents a classification cellular manufacturing systems in the context of cycle time optimization. This work provides formulae for the calculation of manufacturing cycle time for the purpose of effective implementation and management of operations. Furthermore, it considers operational issues for such effective implementation. Keywords: Cellular Manufacturing, CIM, cycle time reduction Product Families Group Technology (GT) is commonly used to identify product families based on similarities in design or processing GT identifies product families with similar processing requirements These families can be manufactured in well-defined manufacturing cells Cellular Manufacturing Group dissimilar machines in manufacturing cell to produce family of parts Work flows in one direction through cell U-shaped for easy access and movement One worker tends several machines Cycle time adjusted by changing number of workers

Manufacturing Cell With One Worker

Manufacturing Cell With Three Workers

Workcells are Flexible Flexible labour o multifunction, adaptable operators o the number of operators can be changed to change capacity Flexible equipment o a variety of products are produced on the same equipment o this requires multifunctional machines o Achievable with basic technology! Linked Workcells and subcells A workcell usually has less than 10 stations, and usually each worker tends more than one station Workcell output (capacity) can be varied by adding or removing workers For complex products, multiple cells can be linked through kanbans or other methods Linked Workcells

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Workcell Design Two main types of cells: Assembly o Hard to automate o Mostly manual Machining o Simpler, easier to automate Cycle Time Cycle time is time interval between completed parts coming from the cell Required cycle time is determined by demand (sometimes called tackt time) Actual cycle time is determined by cell capacity Actual cycle time should be close to required cycle time Required cycle time

Assembly Workcells

Increasing Capacity Add workers and divide cell into subcells Limit: one worker at each station Overall cycle time is equal to cycle time of slowest subcell Alternative: rabbit chase Machining Workcells Usually use automatic, single-cycle machines Worker tasks: o Unload finished part o Setup if necessary o Load new part o Start machine (it runs and stops automatically)

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Machining Cell Cycle Time

Increasing Capacity Again, cell capacity can be increased by adding workers until machine capacity is reached For flexibility, cells should be designed so machines have lots of excess capacity Additional machines can be added if necessary This is most feasible if cost of machine time is low (simple, inexpensive machines) Batch Size = 1 If setup time is very short, products can be made in any order in batch sizes of 1 Since parts are all similar, setup times of a few seconds are achievable Worker Issues Workers must be able to operate a range of equipment and perform a variety of tasks Workers are reassigned to different cells as required by changing demand Equipment Issues Lots of inexpensive machines are better than a few expensive ones They can be allocated to different cells They are easy to relocate Running them at low utilization is not a concern Cell Automation Cells are well suited to automation in some cases Full automation can be expensive, and result in reduced flexibility

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Flexible Manufacturing Systems Automated machining operations Automated material handling Automated tool changers Computer controlled system Designed around size of parts processed & average processing time for parts Can process wide variety of items quickly FMS Layouts

Open Field FMS Layout

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