CELLULAR MANUFACTURING

A  commonly used as a manufacturing approach in which equipment and workstations are arranged to facilitate small lot, continuous flow production. In a cell, all operations that are necessary to produce a product or service for a customer are performed in close proximity, often times in a U-shaped layout, thus allowing for quick feedback between operations when problems and other issues arise. Workers in cells are typically cross trained and able to perform multiple tasks as needed.

A number of larger organizations work together in departments (to make it easiest for the manager of that department), but it is better if they are located by product or service, and sit with others who support that product or service. In an office setting, workers from different departments are co-located near each other in a cell, to increase the work flow, reduce response time to the customer, and break down barriers and silos between departments.

In traditional manufacturing environments, similar machines are placed close together (e.g. lathes, mills, drills, presses, painting, cleaning, etc.). These layouts are more robust to machine breakdowns, have common jigs and fixtures in the same area, and support high levels of demarcation.

In Cellular Manufacturing systems,  machines are grouped together according to the families of parts produced, which provides a distinct advantage in that material flow is significantly improved, which reduces the distance traveled by materials, inventory, people which increases the overall lead times.

Cellular Manufacturing is a lean manufacturing approach that helps companies build a variety of products for their customers with as little waste as possible. In cellular manufacturing, equipment and workstations are arranged in a sequence that supports a smooth flow of materials and components through the process, with minimal transport or delay.

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. The opposite of one piece flow is mass production with batches and queues. One piece flow focuses on flow efficiency rather than on resource efficiency.

Applying one piece flow allows to:

• Minimize stocks and thereby reduce transport and inventory wastes
• Deliver quicker
• Minimize damage, deterioration and obsolescence.

How to operate in a U-shaped Cell?

Reduce travel distance by arranging equipment and workstations closer together. The beginning of the process must be close to the end of the process. The goal is to minimize the travel distance between each steps and cycles.

What do you need in order to implement Cellular Manufacturing?

• Organize your operations and equipment in a logic and validated U-Shaped Cell
• Empower your operators and set multimachine and multiskilled operators as standard
• Favor small, flexible machines
• Using autonomation (Jidoka) to eliminate machine watching

How to design cells for Cellular Manufacturing?

1. Analyse & document the process today (ASISSituation)
2. Define the product family that the cell will produce and calculate the TAKT Time for the cell
3. Balance the work to create flow between work-stations that meets demand constraints
4. Design the cell for ergonomics
5. Implement, test and improve the cell through continuous improvement