CELLULAR MANUFACTURING

PRODUCTION SYSTEM It can be broadly classified as :1. Job Shop Production : Products are made to satisfy a specific

order.2. Batch Production : Number of identical products are

manufactured.3. Mass Production : Same type of products are manufactured to

meet the continuous demand.

CELLULAR MANUFACTURING : HISTORY Cellular manufacturing is derivative of principles of group technology, which were proposed by Flanders in 1925.

Japanese firms began implementing cellular manufacturing sometime in the 1970s.

Cellular manufacturing involves the use of multiple "cells" in an assembly line fashion.

WHAT IS A WORKING CELL ? An ideal cell manufactures a narrow range of highly similar products. Such an ideal cell is self-contained with all necessary equipment and resources.

The result is very fast throughput. Communication is easy since every operator is close to the others. This improves quality and coordination.

Regardless of the cell design (straight line, u-shape, or other), the equipment in the cell are placed very near one another to save space and time. 

CELLULAR MANUFACTURING In this type of technology in manufacturing, all or a portion of a firm’s manufacturing system is converted into cells.

These cells are dedicated to produce similar products or a family of parts.

A manufacture cell produces parts, one at a time, following the sequence of the machines and operations in a lean flow.

It is an application of Group Technology in Manufacturing.

GROUP TECHNOLOGY Here similar products are identified and grouped together to take advantage of their similarities in design and production.

The group of similar parts is known as part family and the group of machineries used to process an individual part is known as Machine cell.

IMPLEMENTATION OF CELLULAR MANUFACTURING SYSTEM IN

GARMENTS INDUSTRY

INTRODUCTION Layout design and the flow of materials have a significant impact on performance of manufacturing system (garments industry) .

These can help to increase productivity, reduce WIP and inventory, short production lead time, streamlines the flow of materials, cost and reduce non value added activities from the production process of waiting and transportation, which make the factory meet customers requirement quickly.

GARMENTS INDUSTRY Most of the apparel industries of India are export oriented. But the industries are operated in such an environment that they are the victim of low labour productivity, high WIP, low labour utilization and higher manufacturing cost, excessive manufacturing lead times.

The most important task for the industry is to reduce the lead time of garment manufacturing.

Successfully implementing Cellular manufacturing allows companies to achieve cost savings and quality improvements, especially when combined with the other aspects of lean manufacturing

GOALS OF THE PROJECT This project has dual purposes: learning and improvement. The situation of the Sewing Floor in the present time needs action towards improvement.

Determination of the present conditions of the Sewing Floor whether it is possible or not possible to introduce cellular manufacturing system.

Determination of the designing and implementation process of cellular manufacturing system in the sewing floor.

Designing a cellular layout for the current sewing line and the measurement of performance.

Some recommendations for successful implementation of cellular manufacturing system in the sewing floor

CELL DESIGN AND IMPLEMENTATION PROCESS PDCA cycle is most useful in continuous improvement, where the process already exists and the PDCA cycle is run over and over again to eliminate the next most important problem, and thus further reduce the variance of the process and its results.

The CAPD cycle on the other hand, is more applicable to planning situations where the target for the next planning cycle is different from the target for the previous one

CAPD cycle was the model used to develop the cell design and implementation process.

STEPS IN CELL DESIGN & IMPLEMENTATION PROCESSAssessmen

t Design Performance Analysis

Implementation

Performance

Measurement

STAGES OF CELL DESIGNAssessment •This stage involves identifying the scopes of this new concept over the existing one•In this stage of the strategy of implementation the area of the all balancing techniques are implemented

Design•The Design step requires that information and feedback are solicited from all the functions and or individuals that are part of the process.•What is desired for the future can be determined in the Design and Performance Analysis steps

Performance Analysis

•Performance Analysis step is a necessary one to check the assumptions and proposals of the design step and to finalize the performance measurements of the cell.

STAGES OF CELL DESIGN

Implementation

•The Implementation step requires mobilizing the people that “do the work” to implement the Changes as for the balancing the line.•Many companies that have tried to implement to implement the cellular manufacturing but there is a big problem associated with mobilizing people and resources to make the balances.

Performance Measurement•The Performance Measurement step is an ongoing process, where performance measurements are monitored to determine the impact of the change in achieving the expected goals.•This step is very important because it establishes the feedback loop needed to identify areas of success and areas where requirements need to be readdressed.

PDCA Vs CAPD Cycle

DATA ANALYSISEXISTING MANUFACTURING SYSTEM OUTPUT

S No. Type Manpower Working Time Time per piece

Total Output per day

1. Full Hand 10 480 25 1902. Half hand 10 480 20 240

PROPOSED SYSTEM

NEW OUTPUTS.N. Type Working

Time(min)Manpower Time per

Piece(min)Output per day

1. Full Hand 480 10 22.5 2102. Half Hand 480 10 15.5 300

RESULT As we can see that by implementing Cellular Technology Productivity for half hand Garments have been gone up by 25% while for Full hand it has been increased by 10%. In the sewing floor of a ready-made garment industry, there exists an ideal environment to use this tool to obtain the benefits of lean manufacturing. Reduces waste Reduction in Manufacturing Costs. Labour productivity increases Provide competitiveness

BENEFITS Reduced work-in-process inventory Less floor space required Shorter flow time of the product, no wait in batches

due to less distance between machines Reduced raw material and finished goods inventory Reduced set up time Heightened sense of employee participation Increased use of equipment and machinery

LIMITATION When new products manufacturing are required, if they do not fit into the existing cell then whole manufacturing set up needs to be restructured. To implement cellular layout cost required is high

THANK YOU