Cell Manufacturing - Project to implement lean manufacturing principles

[bricka]

I am currently in charge of a project to implement lean manufacturing principles in my company.

I would like to find some further information on Cell manufacturing / layouts etc. I have done simulations with U shaped cells etc but I would like to do some reading of my own and be able to correctly educate the shop floor so that they can reach the correct decision when they re-layout the shop floor.

Thanks, Darren.

 

[Stijloor]

Re: Cell Manufacturing

I am currently in charge of a project to implement lean manufacturing principles in my company.

I would like to find some further information on Cell manufacturing / layouts etc. I have done simulations with U shaped cells etc but I would like to do some reading of my own and be able to correctly educate the shop floor so that they can reach the correct decision when they re-layout the shop floor.

Thanks, Darren.

Darren,

Welcome to The Cove Forums!

There is a lot of information available about "Lean" at The Cove Forums.

You can do a search.... Let us know if you need help.

Stijloor.

 

[BradM]

Re: Cell Manufacturing

Hello Darren! Welcome!

There is a lot of stuff on the cellular design. Any Operations Management textbook should give you the basics of it.

A couple of things:

1. Make sure that cellular matches your Strategy. If you are mass production, you will lose efficiency with cellular design. Saying, you have five cells with five stations. Station 3 in cell 1 is a bit behind. Either they will have to wait, or take the work to another station 3. Having homogeneous product flow straight down a line to each station is old-fashioned, but can be the most efficient. Heterogeneous/independent products are another matter.

2. Your physical layout should lend to any re-designed process you desire to do. Too, good process mapping is important here, not only what you currently have, but what you are going to. Make sure you have not missed any steps. For example, ride a day with the forklift operator and find out what they currently do, and what would change for them if you change the layout.

3. The management style will change. It will require a little more project oriented style than process style. A supervisor will need to work with all five stations and know their specialized areas. Also, maintenance of the equipment will change a bit.

That's a few things off the top of my head. It is important to make sure you have covered all the basics in the new design. Otherwise, you may spend a lot of money/ downtime, and not gain much advantage.

 

[wmarhel]

The key reference for Cellular Manufacturing would be: "One-Piece Flow" by Kenichi Sekine. Another option would be "Reorganizing the Factory" by Nancy Hyer

Moving towards manufacturing cells isn't difficult if you've done the groundwork such as looking at historical demand / potential future demand, product mix, specific quality requirements, and those operations that are either performed by monuments (large pieces of equipment that can be difficult to move) or that occur within a process that takes a very long cycle time to complete.

Wayne

 

[bricka]

Thanks for the help guys, I have been a memebr of this Forum for some months and found it extremely useful.

Wayne, thanks for the book advice - I have ordered One-Piece Flow" by Kenichi Sekine.

Cheers, Darren