UNIT 3 CELLULAR

MANUFACTURING
UNIT 3 CELLULAR
MANUFACTURING
Group technology
Part families
Parts classification coding scheme
Production flow analysis
Cellular manufacturing
Machine cell layout
GROUP TECHNOLOGY
Group technology is a manufacturing
philosophy in which similar parts are
identified and grouped together to take
advantage of their similarities in design and
production.

Similar parts are arranged into part families,

where each part family possesses similar
design and manufacturing characteristics.
OBJECTIVES OF GROUP
TECHNOLOGY
Reducing manufacturing lead times

Reducing the waiting time in process

Improve scheduling as they are grouped

Reduce setup time

TRADITIONAL PROCESS LAYOUT
GROUP TECHNOLOGY LAYOUT
 Ways to Identify Part Families
The visual inspection method is the least
sophisticated and least expensive method.
- It involves the classification of parts into
families by looking at either the physical
parts or their photographs and
-arranging them into groups having similar
features.
 2.Production flow analysis - using
information contained on route sheets to
classify parts

3.Parts classification and coding -

identifying similarities and differences
among parts and relating them by means of a
coding scheme
PARTS CLASSIFICATION AND
CODING SYSTEM
.
This is the most time consuming of the three
methods. In parts classification and coding,
similarities among parts are identified, and
these similarities are related in a coding system.

Example: 12345 6789 ABCD

12345-Design Attributes
6789-Manufacturing attributes
ABCD-Production operation and sequence
Parts Classification and Coding
Most classification and coding systems are one of the following:
Systems based on part design attributes
Systems based on part manufacturing attributes
Systems based on both design and manufacturing attributes
Part Design Attributes
Major dimensions
Basic external shape
Basic internal shape
Length/diameter ratio
Material type
Part function
Tolerances
Surface finish

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Parts Classification and Coding
Part Manufacturing Attributes
Major process
Operation sequence
Batch size
Annual production
Machine tools
Cutting tools
Material type

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REASON FOR USING CODING
SYSTEM
Design retrieval system
Automated process planning
Machine cell design

Design retrieval
A designer faced with the task of developing a
new part can use a design retrieval system to
determine if a similar part already exists. A
simple change in an existing part would take
much less time than designing a whole new part
from beginning.
 Automated process planning
-Automated process planning The part code for a new part
can be used to search for process plans for existing parts with
identical or similar codes

Machine cell design

The part codes can be used to design machine cells
capable of producing all members of a particular part
family, using the composite part concept
Parts Classification and Coding
Coding methods:
These are employed in classifying parts into part
families.
Coding refers to the process of assigning symbols to
the parts.
The symbols represent design attributes of parts or
manufacturing features of part families.

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Parts Classification and Coding
The variations in codes resulting from the way the
symbols are assigned can be grouped into three
distinct type of codes:
Monocode or hierarchical code
Polycode or attribute
Hybrid or mixed code

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Monocode or hierarchical code
The structure of Monocode is like a tree in which
each symbol amplifies the information provided in
the previous digit.

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Monocode or hierarchical code

Structure of Monocode
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Monocode or hierarchical code
A monocode (hierarchical code) provides a large
amount of information in a relatively small number of
digits.
Useful for storage and retrieval of design related
information such as part geometry, material, size,
etc.
It is difficult to capture information on manufacturing
sequences in hierarchical manner, so applicability of
this code in manufacturing is rather limited.

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Poly Code
Chain-type structure, known as a polycode, in which
the interpretation of each symbol in the sequence is
always the same; it does not depend on the value of
preceding symbols, so symbols are independent of
each other.
Each digit in specific location of the code describes a
unique property of the workpiece.
It is easy to learn and useful in manufacturing
situations where the manufacturing process have to
be described.
The length of a Polycode may become excessive
because of its unlimited combinational features.

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Poly Code

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Group Technology
Mixed (Hybrid Code)
It is the mixture of both monocode and polycode
systems. Mixed code retains the advantages of both
systems. Most coding systems use this code
structure.

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Group Technology
The OPITZ classification system:
It is a mixed (hybrid) coding system
Developed by H.Opitz, Technical University of
Aachen, GERMANY in 1970
It is widely used in industry
It provides a basic framework for understanding the
classification and coding process
It can be applied to machined parts, non-machined
parts (both formed and cast) and purchased parts
It considers both design and manufacturing
information

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 Group Technology
The Opitz coding system consists of three groups of digits:

Form Supplementary Secondary

code code code
12345 6789 ABCD

part geometry information Production

and features relevant to processes and
relevant to part manufacturing production
design (polycode) sequences

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Opitz System

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27
PRODUCTION FLOW ANALYSIS
PFA is an approach to identify the part
family and associated with machine cell
based on process route sheet.

PFA is consists of four stages

Data collection
Sortation of process routings
PFA Chart
Cluster analysis
 Data collection
- the minimum data is needed in the analysis
of part number and operation sequence which
is contained in shop documents called route
sheets.
-so determining the operation sequence and
machine sequence.
 Sortation of process routings.
in this step the parts are arranged into
groups according to the similarity of their
process routings.
 EXAMPLE:PFA CHART
Consider a problem of 4 machines and 6 parts. Try to
group them.

Components
Machine 1 2 3 4 5 6
s
M1 1 1 1
M2 1 1 1
M3 1 1 1
M4 1 1 1

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 Components(CLUSTER
ANALYSIS)
Machine 2 4 6 1 3 5
s
M1 1 1 1

M2 1 1 1

M3 1 1 1

M4 1 1 1

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33
Rank Order Clustering Algorithm
Step 1: Assign binary weight and calculate a
decimal weight for each row and column
using the following method:

calculation

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 DIFFRENCE BETWEEN PFA&RANK ORDER
CLUSTERING ALGORITHM
PFA:Identifying part families and
associated machine grouping based on
information contained on production route
sheets
Rank order clustering algorithm: formation
of part families and machine cells based
on binary ordering algorithm

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Write binary number

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 WRITE BINARY NUMBER
ROW BINARY NUMBER
NUMBER
1 1111101111
2 0111000011
3 1000111000
4 0111000111
5 1111111100

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ASSIGN BINARY WEIGHT

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Rank Order Clustering Algorithm
Step 2: Rank the rows in order of
decreasing decimal weight values.

Step 3: Repeat steps 1 and 2 for each

column.

Step 4: Continue preceding steps until

there is no change in the position of each
element in the row and the column.
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 Question
Apply rank order clustering technique to
the part machine incidence matrix shown
in table to arrange parts and machine
.groups

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Rank Order Clustering Algorithm
Example:
Consider a problem of 5 machines and 10 parts. Try to
group them by using Rank Order Clustering Algorithm.
Table 1 Components
Machines 1 2 3 4 5 6 7 8 9 10
M1 1 1 1 1 1 1 1 1 1
M2 1 1 1 1 1
M3 1 1 1 1
M4 1 1 1 1 1 1
M5 1 1 1 1 1 1 1 1

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Rank Order Clustering Algorithm
Table 2 Binary weight
29 28 27 26 25 24 23 22 21 20

Components
Machines 1 2 3 4 5 6 7 8 9 10 Decimal
equivalent

M1 1 1 1 1 1 1 1 1 1 1007
M2 1 1 1 1 1 451
M3 1 1 1 1 568
M4 1 1 1 1 1 1 455
M5 1 1 1 1 1 1 1 1 1020
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 Rank Order Clustering Algorithm
Table 3 Binary weight
29 28 27 26 25 24 23 22 21 20
Components
Binary Machines 1 2 3 4 5 6 7 8 9 10
weight
24 M5 1 1 1 1 1 1 1 1
23 M1 1 1 1 1 1 1 1 1 1
22 M3 1 1 1 1
21 M4 1 1 1 1 1 1
20 M2 1 1 1 1 1
Decimal
equivalent 28 27 27 27 28 20 28 26 11 11
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 Rank Order Clustering Algorithm

Table 4 Binary weight

29 28 27 26 25 24 23 22 21 20

Components
Binary Machines 1 5 7 2 3 4 8 6 9 10 Decimal
weight equivalen
t

24 M5 1 1 1 1 1 1 1 1 1020
23 M1 1 1 1 1 1 1 1 1 1 1019
22 M3 1 1 1 1 900
21 M4 1 1 1 1 1 1 123
20 M2 1 1 1 1 1 115
Decimal
equivalent
28 28 28 27 27 27 26 20 11 11
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CELLULAR MANUFACTURING
Cellular manufacturing is an application of
group technology in which dissimilar
machines are arranged and grouped into
machine cells is called cellular
manufacturing.
OBJECTIVES OF CELLULAR
MANUFACTURING
To shorten manufacturing lead times-by
reducing setup,
work part handling time and
waiting time.

To improve quality: this is accomplished by

allowing each cell to specialize in producing
a smaller number of different parts.
COMPOSITE PART CONCEPT
Part families are defined by the fact that
their member have similar design and or
manufacturing features.

The composite part concept takes this part

family definition to its logical conclusion.

The composite part for a given family is a

hypothetical part that includes all of the
design and manufacturing attributes of the
family.
 A machine cell to produce this part family
would be designed with the capability to
accomplish all seven operations required to
produce the composite part.
COMPOSITE PART CONCEPT
COMPOSITE PART FEATURES
MACHINE CELL DESIGN
Group technology machine cells can be
classified according to the number of
machines and the degree to which the
material flow is mechanized between
machines
Single machine cell
Group machine cell with manual handling
Group machine cell with semi integrated
handling
Flexible manufacturing cell or flexible
manufacturing system.
 Group machine cell with semi integrated
handling
-Inline layout
-loop layout
-Rectangular layout
Single machine cell
This type machine cell consists of one
machine plus supporting fixtures and tooling.

This type of machine cell can be applied

which parts have single feature for example
turning or milling operation.
Group machine cell with manual handling
Group machine cell with manual handling

This type of group machine cell is consists of

u shaped layout in which an arrangement of
more than one machine used collectively to
produce one or more part families .

There is no provision for automatic material

handling or semi material handling
equipment's for transfer the parts between
the workstation.
GROUP MACHINE CELLS WITH
SEMI INTEGRATED HANDLING
Group machine cells with semi integrated
handling this type of machine cells is
consists of number machines with
mechanized handling system such as
conveyor to move the parts between the
machines.
Inline layout
Loop layout
Rectangular layout
IN LINE TYPE LAYOUT
IN LINE TYPE LAYOUT
this type of layout machines are arranged as
a line with semi automatic material handling
system for move the parts between the
workstation.
LOOP LAYOUT
LOOP LAYOUT
This type of layout in general uses a
conveyor belt or roller conveyor fro
transferring materials from one machine to
another.

At each machine station a secondary

material handling device handles semi
finished part from primary conveyor and
feeds into machine and after machined part
again handles and feed to primary
conveyor.
RECTANGULAR LAYOUT
UNIT 4 FLEXIBLE MANUFACTURING SYSTEM

FLEXIBLE MANUFACTURING SYSTEM (FMS)

- A FMS is a highly automated GT machine
cell ,consisting of a group of processing
workstations ,interconnected by an
automated material handling and storage
system and controlled by a distributed
computer system.
 FMS can be simply defined as a system that
consists of programmable machine tools
interlinked with automated material
handling system to manufacture wide variety
of good quality parts at different
quantities.
FLEXIBILITY
This FMS System provides flexibility because
of this system have capable of processing
variety of different part styles
simultaneously at the various workstations,
and the mix of part styles and quantities of
production can be adjusted based on demand
IDENTIFIED FLEXIBILITY
We identified three capabilities that a
manufacturing system must possess the
following
-the machine must have produced different
part styles or variety without reducing quality.
-quick changeover of operations instruction
-quick changeover of physical setup
AUTOMATED MANUFACTURING CELL WITH
TWO MACHINE CELL
 To qualify as being flexible ,a manufacturing
should satisfy several criteria
FLEXIBILITY LEVEL CRITERIA
Part variety test

Schedule change test

Error recovery test

New part test

 Part variety test
-can the system process different part styles ?
Schedule change test

-can the system readily accept changes in

production schedule ?
Error recovery test

Can the system recover gracefully from

equipment breakdowns, so that the system
production is not completely disrupted ?
 New part test
Can the system adopt new part design be
introduced ?

If the answer to all of these questions is

yes for a given manufacturing system ,then
system can be considered flexible.
TYPES OF FMS
Single machine cell

Flexible manufacturing cell

Flexible manufacturing system

SINGLE MACHINE CELL
 This system consists one cnc machining
center combined with parts storage system
for unattended operation as shown in fig.

This type of machine can be either operate

1.Batch mode
single part style with lot size production
2.variety part styles mode
-when the system operated in a flexible
mode ,the system satisfy the flexibility test
criteria except 3 level.
FLEXIBLE MANUFACTURING
CELL
FLEXIBLE MANUFACTURING CELL
This type of manufacturing system consists of
TWO OR THREE workstation with part
handling system.
The part handling system is connected to a
load and unload station.

This type of FMS satisfies the four flexibility

test criteria.
FLEXIBLE MANUFACTURING
SYSTEM
This type of manufacturing system has four
or more workstation connected
mechanically by a common part handling
system and electronically by a distributed
computer system.
this system includes non processing
workstation Ex: coordinate measuring
machine.
Each workstation is operated and monitoring
by computer control system
Satisfies the four level criteria
FMS WORKSTATIONS
Load/unloaded stations

Machining stations

Assembly stations

Other processing stations

Load/unloaded stations
This of type stations physical interface
between FMS and the rest of factory.

Raw work parts enter the system at this

point and finished part exit the system from
here.

Loading and unloading operation can be

either manually or automated material
handling.
 Loading and unloading stations should be
ergonomically designed to permit convenient
and safe movement of work parts and also
include material handling equipment such as
cranes or conveyors or robot arm for lifting
heavy weight part.
 Assembly stations
-Some FMS are designed to perform assembly
operations.
-Flexible automated assembly systems are
being developed to replace manual labor in
the assembly of products typically made in
batch products.
- Industrial robots are used for automated
assembly line it can be programmed to
perform variations in sequence and motion
for assembled products.
 Machining stations
-As the name suggest a machining station is
nothing but a station which consist of a
machine or set of machines.

-In most cases FMS uses CNC Machining center

because of its have wide range of tooling setup
to accommodate the variety of product.
-other machining stations for rotational and
non rotational work part like Lathe and milling
machines are used
 Other processing stations
-Apart from regular machining operation there
are operation like punching, bending pressing
and forging workstation used in FMS.
- To increase the flexibility of the system these
processing stations are used.
FMS MATERIAL HANDLING
SYSTEM
Material handling system is mainly helps to
move the parts from raw material place to
workstation place and after finishing the part
unloading from workstation to storage area.
 Functions of FMS Material handling system
Random, independent movement of parts
between workstation.
Handle the variety of part
Provide temporary storage.
Convenient use for loading and unloading
process.
Compatible with computer control.
TYPES OF MATERIAL HANDLING
SYSTEM
Primary material handling
-Handling material between the stations for
example conveyor .

Secondary material handling

the functions of secondary material handling
system is to transfer parts or materials from
primary material handling to loading
stations.
Ex industrial robot
COURSE OUTCOMES OF CIM
Describe the elements of CIM system & an automated system, Production system
C 403.1 and mathematical models of production performance & manufacturing control.

Discuss the use of computers in process planning, different aspects of planning

C 403.2 system and control systems.

Solve the simple problems in part coding system in Group Technology and
C 403.3 quantitative analysis in cellular manufacturing.

Discuss the flexible manufacturing system components, planning & control and
C 403.4 Automated Guided Vehicle System.

Discuss the Robot anatomy, related attributes, and classification of robots, robot
C 403.5 control systems and robot part programming.
FMS COMPUTER CONTROL SYSTEM
This type of FMS computer control system its
helps to interfaced to the workstation and
material handling system and other
hardware components.

Its consists of a central computer and

microcomputer.
central computer- Its coordinates the
activities of the components to achieve
smooth overall operation of the system
 Microprocessors its helps to controlling the
individual machines and other components.
FUNCTIONS OF COMPUTER
CONTROL SYSTEM
Workstation control
Distribution of instruction to the workstation
Production control
Traffic control
Shuttle control
Work piece monitoring
Tool control
Performance monitoring and reporting
FUNCTIONS OF COMPUTER
CONTROL SYSTEM
Workstation control
The different workstation such as
processing station and assembly stations are
controlled by computer control system.

In machining system CNC is used to control

the individual machine tools.
 Distribution of instruction to the
workstation

Distribution of instruction to the workstation

through DNC(Direct numerical control) which
is supported by computer control system for
feeding the operation instruction to the
various machines by programme.
 Production control
-we can control and provide instructions
about raw workparts handling, routing ,loading
/unloading and pallets requirement for holding
raw workparts by computer control system
 Traffic control
-the movement of parts to machines for
various operations or various loading
/unloading stations are controlled and avoid
clash or queuing in stations by computer
control system
 Shuttle control
-this control system handles interaction
between primary handling system and
secondary handling system.
 Work piece monitoring
-computer control system its helps to
monitoring and controlling the movement of
parts between workstation during the loading
and unloading
 Tool control
-tool control is mainly concerned with two
aspects
1.tool locations
2.tool life monitoring

- computer control system its helps to

keeping tool track of the cutting tools at each
workstation for making various parts and also
monitoring tool life based on specified tool life
time.
 Performance monitoring and reporting
computer control system is programmed to
collect data on the operation and performance
of the FMS.
-This data is periodically summarized and
reports are prepared for management on
system performance
FMS APPLICATIONS
Machining operations (turning ,milling
drilling
Creating flexibility for manufacturing
rotational and non rotational parts
Sheet metal works
Forging
Assembly with quality inspections.
FMS BENEFITS
Increased machine utilization- because of
FMS aims for maximum utility of the system
this is achieved by the following
- continuous and break free operations of the
system
-automatic tool /part /product loading and
unloading
-maximum optimizing the operation sequence
to avoid over queuing of parts at station
 Fewer machines required
- because of higher machine utilization,
fewer machines are required.

Reduction in factory floor space nearly 40

% is compare to job shop production
 Greater responsiveness to change.
-adopt new part design, change of new
schedule ,breakfree operation and part design
changes.

Reduced inventories
Lower manufacturing lead time
Less labor requirement and higher
productivity
AUTOMATED GUIDED VEHICLES
An Automated guided vehicle system is a
material handling system that uses
independently operated, driverless vehicle
which is controlled or guided along
predefined paths, and are powered by means
of on board batteries.
Automated guided vehicle system is a
computer controlled self propelled vehicle
used for transporting materials from point
tot point in a manufacturing setting.
Why consider AGVs?
Reduces the labor cost.
Flexible.
Intelligent.
Less time consuming.
Can significantly reduce production & warehouse costs.
Transforming the materials handling industry.
TYPES OF AGV
GUIDED DRIVERLESS TRAINS

GUIDED PALLET TRUCKS

GUIDED UNIT LOAD CARRIERS

GUIDED DRIVERLESS TRAINS
GUIDED DRIVERLESS TRAINS
 GUIDED DRIVERLESS TRAINS
A Driverless trains consists of towing vehicle
that pulls one or more trailers to form a
train.

A common application is transporting large of

bulky and heavy materials from the
warehouse to various locations in the
manufacturing plant.

In order to efficient transport system we can

connect five or ten trailers.
AUTOMATED GUIDED PALLET
TRUCKS
AUTOMATED GUIDED PALLET
TRUCKS
AUTOMATED GUIDED PALLET
TRUCKS
This type of pallet trucks mainly used for
floor level loading and unloading operation.

It is used for picking up or dropping off loads

from and on to floor level.

Thus it eliminates the need for fixed load

stands
GUIDED UNIT LOAD CARRIERS
GUIDED UNIT LOAD CARRIERS
GUIDED UNIT LOAD CARRIERS

AGV unit load carriers are used to move unit

loads from one station to another .

They are often equipped for automatic

loading and unloading of pallets by means of
powered rollers, moving belts ,mechanized
lift platforms and other devices built into the
vehicle deck.
Maximum load capcity 500lb