JAYAVEL.

T
2010220029
Typical Part Families
Items that are made with the same equipment
Items that look alike

A FAMILY OF PARTS
Items that are made with the
same equipment - Production
Flow Analysis
PFA is a technique that uses Operation Routing
Summaries as input. It clusters the parts that
require the same processes. These parts can
then be assembled into a part family. The
processes can be grouped into a cell to
minimize material handling requirements.
Items that look alike
Most products that look similar are
manufactured using similar production
techniques. If parts are grouped because
they have similar geometry (about the same
size and shape), then they should represent a
part family.
Grouping based on
geometry or function
THREE TECHNIQUES TO FORM PART FAMILIES

1. TACIT JUDGMENT OR VISUAL INSPECTION

• MAY USE PHOTOS OR PART

PRINTS
• UTILIZES SUBJECTIVE
JUDGMENT

2. CLASSIFICATION & CODING BY EXAMINTAION

OF DESIGN & PRODUCTION DATA
• MOST COMMON IN INDUSTRY
• MOST TIME CONSUMING &
COMPLICATED
Cont’d
THREE TECHNIQUES TO FORM PART FAMILIES

3. PRODUCTION FLOW ANALYSIS

• USES INFORMATION CONTAINED
ON THE ROUTE SHEET
(THEREFORE ONLY MFG. INFO)
• PARTS GROUPED BY REQUIRED
PROCESSING
Identifying Manufacturing Cells
Using Production Flow Analysis
Production Flow Analysis
• A technique for forming part families based on Operation
Routing Summaries
• Several methods available. We will discuss 2 algorithms for
PFF (Part Family Formation)
Let’s consider 5 parts (n) and 6 machines (m):

n = {101, 102, 103, 104, 105}

m = {Drill1, Drill2, Mill1, Mill2, Vbore1, Vbore2}
= {D1, D2, M1, M2, V1, V2}
Operation Routing Summary
 Create a PFA matrix, M

Parts
101 102 103 104 105
Drill1 1 0 1 0 1
Machines

Drill2 0 1 0 1 0
Mill1 1 0 1 0 1
M = Mill2 0 1 0 1 0
VB1 1 1 0 0 1
VB2 0 0 0 1 0
 King’s Algorithm (Rank Order Clustering)
Step#1
Calculate the total column width for each column
Generate 2i
wj = ∑ 2 i mi
∀i

Part# (j) 101 102 103 104 105 i

Machine# (i) 2
1 D1 1 0 1 0 1 2
2 D2 0 1 0 1 0 4
3 M1 1 0 1 0 1 8
4 M2 0 1 0 1 0 16
5 V1 1 1 0 0 1 32
6 V2 0 0 0 1 0 64

Sum: mi,j * 2i 42 52 10 84 42 (wj)

for each column (wj) Done!
#2. If Wj is in ascending order, go to step #3; otherwise,
rearrange the columns to make Wj fall in an ascending order.

101 105

103 101 105 102 104

∑i
D1 1 1 1 0 0 14
D2 0 0 0 1 1 48
M1 1 1 1 0 0 14
M2 0 0 0 1 1 48
V1 0 1 1 1 1 28
V2 0 0 0 0 0 32
wj 10 42 42 52 84

102

103 104
 #3. ∀i, calculate the total row weight, wi

wi = ∑2 m
∀j
j
ij
Sum: mi,j * 2j
for each row (wi)
103 101 105 102 104
wi
D1 1 1 1 0 0 14
D2 0 0 0 1 1 48
M1 1 1 1 0 0 14
M2 0 0 0 1 1 48
V1 0 1 1 1 1 28
Generate 2j V2 0 0 0 0 0 32
j 2 4 8 16 32
2

Done!
#4. If wi is in ascending order, stop. Otherwise, arrange
rows to make Wi ascend.

103 101 105 102 104

1 1 1 0 0 D1
1 1 1 0 0 M1
0 1 1 1 0 V1 M1
0 0 0 0 1 V2 V1
0 0 0 1 1 D2
0 0 0 1 1 M2 D2 V
2
V2
#5 Stop and make Cells and Part families

103 101 105 102 104

1 1 1 0 0 D1
1 1 1 0 0 M1
0 1 1 1 0 V1
0 0 0 0 1 V2
0 0 0 1 1 D2
0 0 0 1 1 M2
Discussion
• Good rectangles mean that you have very distinctive part families
• Do Parts no 103, 101, 105 have a distinct code so that a F can be
made to distinguish them from #102, 104.
• Cell formation
• Volume / Floor space
• Size of problems
• How about King’s algorithm? Will it always work?
• Are there problems with it?
 DIRECT CLUSTER
ALGORITHM
101 102 103 104 105 wi
D1 1 0 1 0 1 3
D2 0 1 0 1 0 2
M1 1 0 1 0 1 3
M2 0 0 0 1 0 1
V1 1 1 1 0 1 4
V2 0 0 0 1 0 1

Step #1. For , calculate the total no. of positive cells in row, i
I

wi =
∑ M ij
all j
 Sort rows in descending order of the wi values

101 102 103 104 105 wi

V1 1 1 1 0 1 4
D1
D1 1 0 1 0 1 3
D2 M1 1 0 1 0 1 3 No Change
V1
D2 0 1 0 1 0 2
M2 M2 0 0 0 1 0 1
V2 0 0 0 1 0 1 No Change
3 2 3 3 3 1

o ne!
D
Step #2. , calculate the total # of positive cell in each
j
column, j

wj = ∑m
alli
ij
 Sort columns in ascending order.

101 102 103 104 105

V1 1 1 1 0 1
D1 1 0 1 0 1
M1 1 0 1 0 1
D2 0 1 0 1 0
M2 0 0 0 1 0
V2 0 0 0 1 0
3 2 3 3 3

t e!
pl e
Com
So rt
Step #3. For i = 1 to n, move all columns j where mij = 1 to the left
maintaining the order of previous rows.

Observe Elements of Row 1

102 101 103 104 105

V1 1 1 1 0 1
D1 0 1 1 0 1
M1 0 1 1 0 1
D2 1 0 0 1 0
M2 0 0 0 1 0
V2 0 0 0 1 0

Move Column 105 to the left and push column 104 back
For Rows 1,2 & 3: Move the 1’s to the left and push the columns with
the zeroes back

Observe Elements of Rows 2 & 3

102 101 103 105 104

V1 1 1 1 1 0
D1 0 1 1 1 0
M1 0 1 1 1 0
D2 1 0 0 0 1
M2 0 0 0 0 1
V2 0 0 0 0 1

Move Columns 101, 103 & 105 to the left and push column 102 back
 Observe Elements of Row 4

101 103 105 102 104

V1 1 1 1 1 0
D1 1 1 1 0 0
M1 1 1 1 0 0
D2 0 0 0 1 1
M2 0 0 0 0 1
V2 0 0 0 0 1

Move Column 102 to the left and push column 101 back
 Observe Elements of Rows 5 & 6

102 101 103 105 104

V1 1 1 1 1 0
D1 0 1 1 1 0
M1 0 1 1 1 0
D2 1 0 0 0 1
M2 0 0 0 0 1
V2 0 0 0 0 1

Move Column 104 to the left and push column 102 back
 104 102 101 103 105
V1 0 1 1 1 1
D1 0 0 1 1 1
M1 0 0 1 1 1
D2 1 1 0 0 0
M2 1 0 0 0 0
V2 1 0 0 0 0

!
e!
et
pl
om
C
#3
ep
St
Step #4. For j = m to 1, move all rows I, where mij
= 1 to the top maintaining the order of the previous
columns, wij

Observe Elements of Columns 101, 103 & 105: No Change can be made!!
Observe Elements of Column 102

104 102 101 103 105

V1 0 1 1 1 1
D1 0 0 1 1 1
M1 0 0 1 1 1
D2 1 1 0 0 0
M2 1 0 0 0 0
V2 1 0 0 0 0

Move Row D2 upwards and push row D1 down

 Observe Elements of Column 104

104 102 101 103 105

V1 0 1 1 1 1
D2 1 1 0 0 0
M1 0 0 1 1 1
D1 0 0 1 1 1
M2 1 0 0 0 0
V2 1 0 0 0 0

Move Row D2 to the top and push row V1 down

 Observe Elements of Column 104

104 102 101 103 105

D2 1 1 0 0 0
V1 0 1 1 1 1
M1 0 0 1 1 1
D1 0 0 1 1 1
M2 1 0 0 0 0
V2 1 0 0 0 0

Move Rows M2 & V2 upwards and push row V1 down

 104 102 101 103 105
D2 1 1 0 0 0
M2 1 0 0 0 0
V2 1 0 0 0 0
V1 0 1 1 1 1
M1 0 0 1 1 1
D1 0 0 1 1 1

!
e!
et
pl
om
C
#4
ep
St
Step #5. If current matrix is the same as the previous, stop;
else to go 3.
Identify Cells or potential Cells

104 102 101 103 105

D2 1 1 0 0 0
M2
Cell #1
1 0 0 0 0
V2 1 0 0 0 0
V1 0 1 1 1 1
M1 0 0 1 1 1 Cell #2
D1 0 0 1 1 1

Part Family #1 Part Family #2

PFA: Weakness
PFA is suitable mostly for small sized
applications, but it has difficulties
coping with some large cell formation
problems when the Machine-Part Matrix
becomes more complex because of
problem size
References

Production flow analysis for group technology

By John L.Burbridge.
Cellular Manufacturing and facility layout By
Richard. A.WYK
Production automation system By Mikell P
Groover