Cellular Manufacturing Systems ndash; Lecture Series 8.ppt

Cellular Manufacturing Systems – Lecture Series 8 IE 3265 POM R. R. Lindeke, PhD Spring 2005 CMS and its relationship to Job and Flow Shops: We can define the movement in a Job Shop (mathematically) this way for any product i: Pr(1→2)i = Pr(1→3)i = Pr(1→4)i = …= Pr(1→n)I While in a Flow Shop: Pr(1→2)i = 1 and Pr(1→n)i = 0 (n ? 2) In developing CMS manufacturing systems we are trying to make all part flows act like Flow shop mathematics! Examining a Cell in the CMS: CMS and Group Technology (GT) CMS layout are based on recognizing similarities in products – similarities in geometry, size, materials and processing requirements This similar products are collected – “Grouped” instead of being treated as individuals Leads to product families that visit similar equipment and populate their ‘cells’ production schedule Simpler setups like in a Job shop can follow and the workers become multifunctional and responsible for all aspects of a product – and its quality Cells can be scheduled to produce synchronously bringing the various sub-assemblies in as needed at final assembly with greater variety built in CMS and Group Technology (GT) CMS and Group Technology (GT) CMS and Group Technology (GT) Benefits of GT and CMS (Companies Reporting): 52% Report reduction in new part design 10% Report reduction in # of new drawings thru standardization 30% Report reduction in new shop drawings 60% Report reduction in IE time 20% Report reduction in floor space 45% Report reduced scrap 80% Report reduced production and quality costs 69% Report reduced set-up time (cost) Benefits of GT and CMS (Companies Reporting): 70% Report reduced throughput time (even more report better predictability of delivery) 82% Report reduced numbers of overdue orders 42% Report reduced raw-materials inventory 62% Report reduced WIP 60% Report reduced finished goods inventory 33% Report increased employee output/time unit (productivity improvement) Clustering Techniques: the Fundamental Issue in Cell Developme