Cellular Manufacturing Tiffany Dundon Boise State University

Cellular ManufacturingCellular Manufacturing

Tiffany DundonTiffany Dundon

Boise State UniversityBoise State University

What will be CoveredWhat will be Covered

• Definition Definition • BrainstormingBrainstorming• Nuts and BoltsNuts and Bolts• Reported Benefits of Cellular ManufacturingReported Benefits of Cellular Manufacturing• How It WorksHow It Works• Examples of Cellular ManufacturingExamples of Cellular Manufacturing• An ExerciseAn Exercise• ConclusionConclusion

Cellular Manufacturing Cellular Manufacturing (CM) Defined(CM) Defined

““Cellular Manufacturing organizes Cellular Manufacturing organizes the entire process for similar the entire process for similar products into a group of team products into a group of team

members, includes all the members, includes all the necessary equipment and is known necessary equipment and is known

as a "Cell".as a "Cell".

Merryman, Wes. Merryman, Wes. Cellular ManufacturingCellular Manufacturing.Online. Internet..Online. Internet.Available at Available at

http://www.ciras.iastate.edu/CIRASnews/cellular.htmlhttp://www.ciras.iastate.edu/CIRASnews/cellular.html

Cellular Manufacturing Cellular Manufacturing DefinedDefined

“…“…The cells are arranged to easily The cells are arranged to easily facilitate all operations. Parts are facilitate all operations. Parts are

handed off from operation to handed off from operation to operation eliminating setups and operation eliminating setups and

unnecessary costs between unnecessary costs between operations.”operations.”

Merryman, Wes. Merryman, Wes. Cellular ManufacturingCellular Manufacturing.Online. Internet..Online. Internet.Available at Available at

http://www.ciras.iastate.edu/CIRASnews/cellular.htmlhttp://www.ciras.iastate.edu/CIRASnews/cellular.html

BrainstormingBrainstorming

• Brainstorm some ideas about Brainstorm some ideas about cellular manufacturingcellular manufacturing

• How can this tool be used in your How can this tool be used in your organization?organization?

Nuts and BoltsNuts and Bolts

• Elimination of wastes by linking stepsElimination of wastes by linking steps– Waste is any resource not adding value Waste is any resource not adding value

to the product being manufacturedto the product being manufactured

• In a cell, most work stations are close In a cell, most work stations are close together so that little or no time is together so that little or no time is required to move partsrequired to move parts


• Cell teams are cross trained in cell Cell teams are cross trained in cell operationsoperations– Continuous improvementContinuous improvement– Reduce lead timesReduce lead times– Remove wasteRemove waste– Improve qualityImprove quality

• Product flow is more visibleProduct flow is more visible– Easier controlEasier control


• Primary purpose:Primary purpose:– Reduce cycle timeReduce cycle time– Reduce inventoriesReduce inventories

• Other benefits include:Other benefits include:– Space reductionSpace reduction– Quality improvementQuality improvement– Labor cost reductionLabor cost reduction– Improved machine utilizationImproved machine utilization


• Human resource issues:Human resource issues:

– Proper training for operatorsProper training for operators

– Cross functional trainingCross functional training

– Team building training for operatorsTeam building training for operators


• Human Resource issues:Human Resource issues:

– Supervisors become coachesSupervisors become coaches

– Compensation (incentives)Compensation (incentives)

– Initial resistance of CMInitial resistance of CM

– Cells need supportCells need support

Reported Benefits of Reported Benefits of CMCM

• Production and Quality Control Cost Production and Quality Control Cost 80%80%

• Setup Time 69%Setup Time 69%

• Throughput time 70%Throughput time 70%

• Overdue orders 82%Overdue orders 82%

Reported Benefits of Reported Benefits of CMCM

• Raw Materials Inventory 42%Raw Materials Inventory 42%

• Finished Goods InventoryFinished Goods Inventory 60% 60%

• Employees Output per unit time Employees Output per unit time 33%33%

Kok, Alvin Lim Hui. Kok, Alvin Lim Hui. Time Based ManufacturingTime Based Manufacturing. Journal of . Journal of Operations Management. 7 July 1999Operations Management. 7 July 1999

How it WorksHow it Works

• Members of the plant team need to Members of the plant team need to be involved in the changesbe involved in the changes

• Other functions need to be Other functions need to be changed:changed:– Production planning and controlProduction planning and control– PurchasingPurchasing– Cost accountingCost accounting

How it worksHow it works

• Where do you begin?Where do you begin?

• First, define the “cells” by the First, define the “cells” by the following criteria:following criteria:– Processes requiredProcesses required– Part numbers and attributesPart numbers and attributes– Market segments / customersMarket segments / customers– Degree of automationDegree of automation


• Team selection is crucialTeam selection is crucial– Identify important skills needed such Identify important skills needed such

as teamwork and leadership skillsas teamwork and leadership skills

– Create a process mapCreate a process map

– Develop a checklist for selecting Develop a checklist for selecting membersmembers


• Match skills to tasksMatch skills to tasks– Create a matrix to define who is best Create a matrix to define who is best

qualified for each taskqualified for each task

• Develop team trust and motivationDevelop team trust and motivation– Manage team moraleManage team morale– Encourage teamworkEncourage teamwork

Real World ExampleReal World Example

John DeereJohn Deere• Integrated welding work cellsIntegrated welding work cells

• Utilizes robotic welding processesUtilizes robotic welding processes– Faster weld timesFaster weld times– Consistent weldsConsistent welds– EnduranceEndurance


John DeereJohn Deere• Major benefits of CM:Major benefits of CM:

– Switching of welds is simpleSwitching of welds is simple– Factory has maximum flexibilityFactory has maximum flexibility– Delivers higher qualityDelivers higher quality– Faster deliveryFaster delivery


InscapeInscape• Production divided into highly Production divided into highly

specialized “cells”specialized “cells”– Each cell contains equipment, Each cell contains equipment,

technology and peopletechnology and people– Each cell can make a wide variety of Each cell can make a wide variety of

family productsfamily products


InscapeInscape• Major benefits of CM:Major benefits of CM:

– Consistently high qualityConsistently high quality– Flexibility for customersFlexibility for customers– Quick changes in size and styleQuick changes in size and style– Mass customizationMass customization

A Short ExerciseA Short Exercise

• How is implementing CM useful in How is implementing CM useful in your organization?your organization?

• How will you define cells? Form How will you define cells? Form teams? Motivate and develop teams? Motivate and develop trust? Change functions? Change trust? Change functions? Change the plant layout?the plant layout?

SummarySummary

• CM: based on a group of different CM: based on a group of different processes located in close processes located in close proximity to manufacture similar proximity to manufacture similar productsproducts

• You must first define the “cells” You must first define the “cells” and then develop a teamand then develop a team

SummarySummary

• Training and support are key Training and support are key elementselements

• Many reported benefits to Many reported benefits to switching your organization to switching your organization to cellular manufacturingcellular manufacturing– Reduce inventories, and moreReduce inventories, and more

ReferencesReferencesJohn Deere. State-of-the-art Robotic Welding. Online. Internet. 3 May John Deere. State-of-the-art Robotic Welding. Online. Internet. 3 May

2002. Available at 2002. Available at http://customer.com/en_za/ag/service/roboticwelding.htmlhttp://customer.com/en_za/ag/service/roboticwelding.html

Inscape Solutions. Cellular Manufacturing. Online. Internet. 29 April Inscape Solutions. Cellular Manufacturing. Online. Internet. 29 April 2002. Available at 2002. Available at http://www.inscapesolutions.com/products/cellular.htmlhttp://www.inscapesolutions.com/products/cellular.html

Kok, Alvin Lim Hui. Kok, Alvin Lim Hui. Time Based ManufacturingTime Based Manufacturing. Journal of Operations . Journal of Operations Management. 7 July 1999Management. 7 July 1999

Merryman, Wes. Merryman, Wes. Cellular ManufacturingCellular Manufacturing.Online. Internet..Online. Internet.15 April 2002. Available at 15 April 2002. Available at http://www.ciras.iastate.edu/CIRASnews/cellular.htmlhttp://www.ciras.iastate.edu/CIRASnews/cellular.html

Patel, Jay. Patel, Jay. Cellular ManufacturingCellular Manufacturing. Online. Internet. 10 April 2002. . Online. Internet. 10 April 2002. Available at http://qpsconsulting.com?cellularmanufacturing.htmAvailable at http://qpsconsulting.com?cellularmanufacturing.htm

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Cellular Manufacturing Tiffany Dundon Boise State University