CELLULAR MANUFACTURING

LAYOUT DESIGNING
Our objective is to design an optimized layout
Need of Plant Layout
• A new plant is to be set up.
• Some new product is to be added to the existing line.
• To improve the space utilization
• To make efficient movement patterns
• There is proposed variation in the size of the departments
• There is an expansion of the enterprise
Types of Plant Layout
• Product or Line Layout
• Process or Functional Layout
• Fixed Position Layout
• Combination type of Layout
Cellular Manufacturing
• To improve production, it is not enough to improve operations in the factory. A Companies
must also improve their processes.
• Cellular Manufacturing is a model for workplace design, and has become an integral part of
lean manufacturing systems.
• It takes full advantage of the similarity between parts, through standardization and common
processing and groups them into cell.
• It is an application of group technology inmanufacturing.
• A Cellular manufacturing can be implemented by manual or automated methods.
Advantages of Cellular Manufacturing
• Reduction in setup time
• Reduction in work in progress
• Reduction in material handling cost and time
• Reduction in material flow distance
• Improvement in machine utilization
• Reduction in production lead time
• Improvement in quality
• Better worker morale
Methodology Start

Problem Identification

Literature Survey

Calculation

Designing

Simulation

Conclusion
Product list
Roof

Hood
Quarter Panel
Spoiler
Bumper
Hub Cap
Grip Handle
Rim
Grill
Rotor Disc
Machines and Process used for the Products are given below:
Calculations
Rank Order Clustering Technique
I. Reading the series of 1’s and 0's in each row as a binary number and converting the binary
value of each row to its decimal equivalent. The values are then ranked in the far-right hand
column in Table 1.

II. Identifying the order of each the rows.

III. Rearranging the rows according to the order in descending.

IV. Reading the series of 1's and 0's in each column from top to bottom as a binary number and
converting the binary value of each column to its decimal equivalent. The values are then
ranked in the bottom column in Table 2.
V. Identifying the order of each the columns.

VI. Rearranging the columns according to the order in descending.

VII.We see that the column order is different from the preceding matrix. Proceeding from step 6
back to steps 1 and 2, we see that a reordering of the columns provides a row order that is in
descending value and the algorithm is concluded (step 7). The final solution is shown in
Final Table; a close comparison of this solution with Final Table reveals that they are the
same part-machine grouping.
Table 1
Table 2
Table 3
LAYOUT DESIGNING
Softwares Used
1. Autodesk AUTOCAD Mechanical 2018
2. Autodesk Inventor
3. Autodesk Factory Design Utilities
2-D Layout
3-D Layout
CELL DIVISION
Factory Layout Cell Divisions
• The factory layout contains of Three cells divided by the required processes and machines

 CELL 1 – SHEET METAL

 CELL 2 – POLYMERS
 CELL 3 – METALLIC
Cell 1 – Sheet Metal
ROOF

SHEET
SPOILER META HOOD

QUARTE
R PANEL
Cell 2 – Polymers

HUB CAP

GRIP
BUMPER
HANDLE

POLYMERS
Cell 3 – Metallic

RIM

METALLI
C

ROTOR
GRILL
DISC
Future scope
This project focuses on layout of plant for reducing the complexity of multiple machines
existing for multiple operation and for that we used rank order clustering technique but it is
not just layout that affect the productivity of an industry. Therefore, we think that further
improvement in following field can be more helpful:

1. Material handling
2. Inventory control
3. Worker ergonomics
4. Space ergonomics