ABSTRACT
Manufacturing cells designed to produce a family of parts by combining heterogeneous machines and cross-trained workers have proven effective in moderate variety discrete parts manufacturing. ... Models are tested using data from the furniture and other manufacturing industries. ... Cells are conducive to single-piece and one-touch manufacturing methods and are often found as part of lean manufacturing applications. ...
Implementing Cellular Manufacturing:
Program Introduction
By combining the concepts of flow production and upgraded operator skills, production processes can become much more streamlined and significant productivity gains can be achieved. ... This program will outline how these concepts are achievable through the implementation of cellular manufacturing. ...
Elements covered include:
• Traditional manufacturing versus Cellular Manufacturing
• Designing U-shaped and Parallel Line Cells
• One-piece flow versus Batch production
• Characteristics of One Piece Flow
• Pull systems versus Push systems
• Pull system characteristics
• The concept of Autonomation
• Understand the Kanban concept
• Examples of Takt Time calculations
• Measuring & Balancing to Takt Time
• Understanding work combination tables
• How to maximise flexible manpower systems to minimise overtime costs
• How cellular manufacturing eliminates manpower out of balance within a normal production system
• Factory of the future. creating a vision
• The principles of "how to identify waste"
• Flow process analysis
Lean Manufacturing
Program Introduction
Understand the principles of Lean Manufacturing and how these principles can be implemented in your organisation. Appreciate how Lean Manufacturing can lower the cost of production by changing the processes used to manufacture the product by transforming time spent on "non value adding" activities into "value adding" activities. ...
Module Content
The steps to lean manufacturing
• Understand the principles and aims of Lean Manufacturing. ...
Elements covered include:
• Identification of the 7+1 forms of waste
• Understand the principles of Takt & Cycle Time
• The concept of Plan Do Check Act (PDCA) & Standardise Do Check Act (SDCA)
• Workplace organisation & The 5S’s
• Visual management techniques
• Poka Yoke (One-Way Fit)
• Optimum Shop floor Layouts
• Cellular Manufacturing Design
• Kanban & Just In Time (JIT)
• TPM - Total Productive Maintenance
• SMED - Single Minute Exchange of Dies
• SAPS - Problem Solving Techniques
• Getting the best out of your people
• Team Working & Team Leadership
• Flexible Manning
• Autonomation & Jidoka
• Single Piece Flow
• Standardising Processes
• Flexible Layouts
• Inventory Reduction
• Continuous Work Flow
• Machine Efficiencies
• ‘Pull’ verses ‘Push’ Systems
Supplier Appraisal
Program Introduction
The objective is to provide a full understanding of the total procurement process and its interface with the supply base. ...
Cellular Manufacturing is used to ensure maximum flexibility and control at all times. ...
Group technology
Group technology or families-of-parts concepts are often used in cellular design. ... in contrast a sub-assembly operation or assembly can be configured in a cellular arrangement.
Cellular configurations can be in several forms: straight line, u-shape, but equipment contained with the cell, or workstations, are normally configured in closely promimity to compress time and space. ...
Facilities Design and Cellular Manufacturing Systems Design
This has produced a number of practical methods for the design or redesign of cellular manufacturing facilities, including:
• Cell formation with important practical issues (e. ... )
• Cell and shop layout for designing cells and placing them on the available shop-floor area
• Material handling flow path (aisle) design for finite capacity material handling on aisle and fixed construction costs
In this work, we consider the design of material handling flow paths in a discrete part manufacturing facility.
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