GROUP TECHNOLOGY

By-

PGDIE 41

Sagar Gawali (Roll-71) Sahil Mahajan (Roll-72) Saikat Saha (Roll-73)

Saloni Dave

(Roll-74)

Santosh Kumar (Roll-75)

What is GT
2

Manufacturing philosophy in which the parts having similarities (Geometry, manufacturing process and/or function) are grouped together to achieve higher level of integration between the design and manufacturing functions of a firm This type of manufacturing in which a part family is produced by a machine cell is known as cellular manufacturing The group of machineries used to process an individual 3/23/2012 part family is known as machine cell

Group Technology System

3

There exist two primary types of GT systems

1. 2.

Cellular Manufacturing GT coding and classification System

Design

Purchasing

Manufacturing

Assembling

Shipment

Typical Process/ Manufacturing Environment

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1. Cellular Manufacturing(CM)
4

1.

The goal of Cellular Manufacturing (CM) is to exploit existing manufacturing process by groupings parts with similar processing requirements to form GT Cells This can be visualized as physical grouping of certain machines/ Process equipments used for manufacturing, to small area which produce a family of similar products. Each Part can be completely processed within the cell

2.

3.

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Existing System vs. Cellular Manufacturing System

5

Existing Process Layout

Finis h

Debur 1
Debur 3

Debur 2
Debur4

Drill 1

Drill 2

Drill 3

Grinder 1
Grinder 3

Grinder 2
Grinder 4

Start

SAW 1 SAW 3

SAW 2 SAW 4

Mill 1 Lathe 1 Lathe 2 Lathe 3 Mill 3

Mill 2 Mill 4

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Contd..
6

CM GT Cell
Lathe 3 Raw Material Saw 1 Grinder 3

Finished Product

Drill 1 Debur 1 Mill 1

Reduction in cycle time

Move time Queue time Set up time
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Where do CM GT Cell Fit in manufacturing Matrix III. Few Major IV. High
I. Low Volume Standardization I. Jumbled Flow (Job Shop) II. Multiple Products, Low Volume Products, higher Volume Commerci al Printer

No Companies

Volume, High Standardizati on

II. Disconnected Flow

III. Connected Line Flow (Assembly Line)

CM GT Cell

Heavy Equipme nt

Automobi le Assembly

IV. Continuous Flow 7

No Companies
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Sugar Refinery

Lowering the Batch Size

8

By Grouping the equipment in the CM results, complete cycle of the one product/part. Considering the Batch size reduction here.
Total Time = 3000mins

Alternative 1

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Reduction of Total Time to 1750 mins from 3000 Total Time = mins 1750mins
Alternative 2

Note:- Reducing the Batch Size eventually to 1 No. will create JIT Scenario

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2. GT coding and classification System

The goal of GT coding and classification is to exploit similarities in part designs and characteristics. The system consists of two activities.
1.

2.

Each part or subcomponent is assigned a code based on a coding scheme that describes various attributes of the part. Parts are classified into families based on similar attributes, such as geometric shape, type of material, machine requirements, or tolerance requirements. Ideally, the coding scheme should include both design and manufacturing attributes of the part.

The GT code shown for this part consists of nine digits, each representing a particular design or manufacturing attribute.

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Example GT coding
Part Number: R4851 GT Code: 34lPS0117 Description: hollow shaft with external key Interpretation of GT Code GT Code: 3 4 1 P S 0 1 1 7 Side View
Key

Front View

Field
Field
1

1
Code
1 2 3 1 2 3 4 1 2 R S P R Sheet Metal Metal Block Bar Stock High Carbon Steel Low Carbon Steel Aluminum Alloy Stainless Steel Interior cavity No interior cavity

7
Field

8
1

9
Code
0
1 0 1 3 5

Description

Description
Interior Surface features

6
7

No interior surface features

exterior suface features no exterior features 0.001 0.003 0.005

0 1

4 1 P S

8 (interior tolerances inches)

7
9 1 3 5 7 9

0.007
0.009 0.001 0.003 0.005 0.007

rough interior finish smooth interior finish polished interior finish rough exterior finish smooth exterior finish polished exterior features 9 (exterior tolerances inches)

S P

11

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12

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Part Number

1
Machine Number

2 1

5 1

1 1 1 1

1 1 1

3
4

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1 MC-1
2 3 MC-2 4

1
1

1
1 1 1 1 1 1

PF-1

PF-2

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Step 0.

Set iteration number k=1

Step 1.

Select any row I of incidence matrix A(k) and draw horizontal line hi through it

Step 2.

For each entry l on the intersection with the horizontal line hi, draw a vertical line vj

Step 3.

For each entry l crossed by vertical line vj draw a horizontal line hi

Step 4.

Repeat steps 2 and 3 until there are not any single crossed entries l left. All double crossed entries l form corresponding machine cell MC-k and part family PF-k

Step 5.

Transform the incidence matrix A(k) into A(k+1) by removing rows and columns corresponding to all horizontal and vertical lines drawn in steps 1 through 4

Step 6.

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Part
Gear Lever Pisto n 1 1 1 1 1 1 V1 V2 V4 1 1 h5 h6 crank 1 1 h3 Cran k arm h1

Milling
Lathe

Machine

Grinding Broaching Boring Drilling Gear hobbing

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Part
Piston Crank arm 1 1

Machine

Lathe
Broaching

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Part
Gear cran Leve k r Milling Boring 1 1 1 1 1 1 1 1 1 1 1 Pist on Cran k arm

Machine

Drilling
Grinding Gear hobbing Lathe Broaching

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Part Number
1 1 2 1 1 1 1 2.5 8 70 1 1 1 1 6 15 1 5 1 10 7 2 1 3 1 1 1 1 1 1 1 1 2 30 4 1 4 5 6 7 1 1 1 8 9 10 11

Machine Number

3 4 5 6 7

Subcontracting Cost
1
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Step 0 : Set k=1 and N=4 Step 1 : Part 3 with the maximum production cost C= 70 has been selected line V3 is drawn.
1 1 2 1 2 1 3 1 1 4 5 6 7 1 1 8 9 10 11 h1

1 1
1 1 2.5 8 70

1 h4

A1 =

4
5 6 7

1
1 1 1 6 15

1
1 1 1 5 1 10 7 1 1 2 30 4 1

h7

20

v3

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Step 2

Since machine 1,4 and 7 are required to process part 3, lines h1,h4 and h7 drawn. Corresponding machine 1,4 and 7 are included in machine cell MC-1.

Step 3 The set V(1) = ( 1, 2, 4, 6, 7, 9) 1 1 2 3 4 1 1 1 1 2 1 3 1 1 1 4 5 6 7 1 1 1 h4 8 9 10 11 h1

5 6
7 2.5 8 v 2

1 1
1 70 v3

1 1
1 1 10 v7 7

1
1 6 15 3 5 v6

1
1 2

1
h7 30 4
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Step 4 From previous matrix: MC-1 = (1,4,7) and PF-1=(2,3,6,7) are obtain Step5 So matrix-3 can be transformed into matrix-4

5 2 1

10

11 1

3
A2 = 5 6 15 1 1 1 7

1 30 4

4
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Step 6 Set k=k+1=2 and go for step 1. and second iteration (k=2) resulted in MC-2= (2,3,5,6) and PF-2 = ( 5,8,10,11), as shown in matrix 5
5 2 3 A2 = 5 6 15 v5 1 1 1 7 v8 1 30 v1 0 4 1 1 8 10 11 1 1 h2

h3
h5 h6

v11

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The final result generated by the cost analysis algorithm in matrix 6

2 1 7 4 2 1 3 1 1 1 7 1 1 1 1 1 1 1 1 1 1 6 11 5 8 10 1 4 9

5 3
6 8 70 10 5 4 6

1 1

1 1
1 1 30 1 1 1 2

15

2.5 6

Machine cells MC-1 and MC-2 and corresponding part families PF-1 and PF-2 a marked with colors. Parts 1, 4, and 9 with the total cost of c1+c4+c9 = 2.5+6+2 Are to be subcontracted.
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Some of the well-known tangible and intangible benefits of implementing GT : 1. Engineering design

Reduction in new parts design Reduction in the number of drawings through standardization Reduction of drafting effort in new shop drawings Reduction of number of similar parts, easy retrieval of similar functional parts, and identification of substitute parts
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2. Layout planning

Reduction in production floor space required Reduced material-handling effort

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3. Specification of equipment, tools, jigs, and fixtures

Standardization of equipment Implementation of cellular manufacturing systems Significant reduction in up-front costs incurred in the release of new parts for manufacture

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4. Manufacturing: process planning

Reduction in setup time and production time Alternative routing leading to improved part routing Reduction in number of machining operations and numerical control (NC) programming time

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5. Manufacturing: production control

Reduced work-in-process inventory Easy identification of bottlenecks Improved material flow and reduced warehousing costs Faster response to schedule changes Improved usage of jigs, fixtures, pallets, tools, material handling, and manufacturing equipment
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6. Manufacturing: quality control

Reduction in number of defects leading to reduced inspection effort Reduced scrap generation Better output quality Increased accountability of operators and supervisors responsible for quality production, making it easier to implement total quality control concepts.
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7. Purchasing

Coding of purchased part leading to standardized rules for purchasing Economies in purchasing possible because of accurate knowledge of raw material requirements Reduced number of part and raw materials Simplified vendor evaluation procedures leading to just-in-time purchasing
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