15ME404

COMPUTER ADIED MANUFACTURING

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Content
Group Technology/ Coding systems

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Group Technology

Batch manufacturing is estimated to be the most

common form of production in the United States,
constituting more than 50% of total
manufacturing activity.
There is a growing need to make batch
manufacturing more efficient and
productive.
In addition, there is an increasing trend toward
achieving a higher level of integration between the
design and manufacturing functions in a firm.
An approach directed at both of these objectives
is group technology (GT). 3
Group Technology

Group technology is a manufacturing philosophy

in which similar parts are identified and grouped
together to take advantage of their similarities in
design and production.
Similar parts are arranged into part families, where
each part family possesses similar design and/or
manufacturing characteristics.
For example, a plant producing 10,000 different
part numbers may be able to group the vast
majority of these parts into 30-40 distinct families.

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Group
Technology
The manufacturing efficiencies are generally
achieved by arranging the production equipment into
machine groups or cells, to facilitate work flow.
Grouping the production equipment into machine
cells, where each cell specializes in the production of
a part family, is called cellular manufacturing.

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Group
Technology
GT is most appropriately applied under the following
conditions:
The plant currently uses traditional batch
production and a process type layout and this
results in much material handling effort, high in-
process inventory, and long manufacturing lead
times.
The parts can be grouped into part families. This
is a necessary condition. Each machine cell is designed
to produce a given part family or limited collection of
part families, so it must be possible to group parts made
in the plant into families.
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Group
Technology
There are two major tasks that a company must undertake
when it implements group technology. These two tasks
represent significant obstacles to the application of GT.
Identifying the part families. If the plant makes
10,000 different parts, reviewing all of the part drawings
and grouping the parts into families is a substantial task
that consumes a significant amount of time.
Rearranging production machines into machine
cells. It is time consuming and costly to plan and
accomplish this rearrangement and the machines are not
producing during the changeover.

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Group Technology - Part Families
Group technology offers substantial benefits to companies
that have the perseverance to implement it. The benefits
include:
GT promotes standardization of tooling, fixturing and
setups.
Material handling is reduced because parts are moved
within a machine cell rather than within the entire factory.
Process planning and production scheduling are
simplified.
Setup times are reduced, resulting in lower
manufacturing lead times.
Work-in-process is reduced.
Worker satisfaction usually improves when workers
collaborate in a GT cell.
Higher quality work is accomplished using group
technology.
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Group Technology - Part Families

Part Families
A part family is a collection of parts that are similar either
because of geometric shape and size or because similar
processing steps are required in their manufacturing.
A group of parts that possess similarities in geometric
shape and size, or in the processing steps used in their
manufacture
Part families are a central feature of group technology
There are always differences among parts in a family
But the similarities are close enough that the parts can be
grouped into the same family

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Group Technology - Part
Families
Two parts that are identical in shape and size
but quite different in manufacturing:
(a)1,000,000 units/yr, tolerance = ±0.010 inch, 1015
CR steel, nickel plate (CR = Cold Rolled )
(b)100/yr, tolerance = ±0.001 inch, 18-8
stainless steel

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Group Technology - Part
Families
Ten parts that are different in size and shape, but
quite similar in terms of manufacturing
All parts are machined from cylindrical stock by
turning; some parts require drilling and/or milling

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Group Technology - Part Families
The biggest single obstacle in changing over to
group technology from a conventional production
shop is the problem of grouping the parts into
families.
There are three general methods for solving this
problem, which involve the analysis of much data
by properly trained personnel.

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Group Technology - Part
Families
1) Visual inspection - using best judgment to group parts
into appropriate families, based on the parts or photos of the
parts
2) Production flow analysis - using information contained
on route sheets to classify parts
3) Parts classification and coding - identifying similarities
and differences among parts and relating them by means of
a coding scheme

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Group Technology

1) The visual inspection method is the least

sophisticated and least expensive method. It
involves the classification of parts into families
by looking at either the physical parts or their
photographs and arranging them into groups
having similar features.
Although this method is generally considered to
be the least accurate of the three, one of the first
major success stories of GT in the United States
made the changeover using the visual inspection
method.

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Group
Technology

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Group
Technology
2) Production flow analysis:
Parts that go through common operations are grouped
into part families.
The machines used to perform these common
operations may be grouped as a cell, consequently this
technique can be used in facility layout (factory layout)

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Group
Technology
Initially, a machine—component chart must be
formed. This is an M x N matrix, where
M = number of machines
N = number of parts
x = 1 if part j has an operation on machine i; 0
otherwise.
If the machine—component chart is small, parts
with similar operations might be grouped together
by
manually sorting the rows and columns.
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Group
Technology

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Parts Classification and Coding
3) Parts Classification and Coding
This is the most time consuming of the three
methods. In parts classification and coding,
similarities among parts are identified, and
these similarities are related in a coding system.

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Parts Classification and
Coding
Most classification and coding systems are one of the following:
Systems based on part design attributes
Systems based on part manufacturing attributes
Systems based on both design and manufacturing attributes
Part Design Attributes
Major dimensions
Basic external shape
Basic internal shape
Length/diameter ratio
Material type
Part function
Tolerances
Surface finish

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Parts Classification and
Coding
Part Manufacturing Attributes
Major process
Operation sequence
Batch size
Annual production
Machine tools
Cutting tools
Material type 22
Parts Classification and Coding

Classification and coding systems are devised to

include both a part's design attributes and its
manufacturing attributes. Reasons for using a
coding scheme include:
Design retrieval A designer faced with the task of
developing a new part can use a design retrieval
system to determine if a similar part already
exists. A simple change in an existing part would
take much less time than designing a whole new
part from scratch.

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Parts Classification and
Coding
Automated process planning The part code for a new part
can be used to search for process plans for existing parts
with identical or similar codes.
Machine cell design The part codes can be used to design
machine cells capable of producing all members of a
particular part family, using the composite part concept.

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Parts Classification and
Coding
Coding methods:
These are employed in classifying parts into part
families.
Coding refers to the process of assigning symbols to
the parts.
The symbols represent design attributes of parts or
manufacturing features of part families.

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Parts Classification and
Coding
The variations in codes resulting from the way the
symbols are assigned can be grouped into three
distinct type of codes:

Monocode or hierarchical code

Polycode or attribute
Hybrid or mixed code

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Monocode or hierarchical
code like a tree
The structure of Monocode is
which each symbol amplifies the information
in
provided in the previous digit.

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Monocode or hierarchical
code

Structure of Monocode
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Monocode or hierarchical
code
A monocode (hierarchical code) provides a large
amount of information in a relatively small number of
digits.
Useful for storage and retrieval of design related
information such as part geometry, material, size,
etc.
It is difficult to capture information on manufacturing
sequences in hierarchical manner, so applicability of
this code in manufacturing is rather limited.

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Poly
Code
Chain-type structure, known as a polycode, in which
the interpretation of each symbol in the sequence is
always the same; it does not depend on the value of
preceding symbols, so symbols are independent of
each other.
Each digit in specific location of the code describes a
unique property of the workpiece.
It is easy to learn and useful in manufacturing
situations where the manufacturing process have to
be described.
The length of a Polycode may become excessive
because of its unlimited combinational features. 32
Poly
Code

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Group
Technology
Mixed (Hybrid Code)
It is the mixture of both monocode and polycode
systems. Mixed code retains the advantages of both
systems. Most coding systems use this code
structure.

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Some of the important
systems
Opitz classification system –the University
of Aachen in Germany, nonproprietary, Chain type.
Brisch System –(Brisch-Birn Inc.)
CODE (Manufacturing Data System, Inc.)
CUTPLAN (Metcut Associates)
MultiClass (OIR: Organization for Industrial
DCLASS (Brigham Youngor
hierarchical University)
decision-tree coding
Research),
structure
Part Analog System (Lovelace, Lawrence &
Co., Inc.)
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Group
Technology
The OPITZ classification system:
It is a mixed (hybrid) coding system
Developed by Opitz, Technical University of Aachen,
1970
It is widely used in industry
It provides a basic framework for
understanding the classification and coding process
It can be applied to machined parts,
non-machined parts (both formed and cast) and
purchased parts 38
 Group
Technology
The Opitz coding system consists of three groups of
digits:

Form Supplementary Secondary

code code code
12345 6789 ABCD

part geometry information Production

and features relevant to processes and
relevant to part manufacturing production
design (polycode) sequences

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Opitz
System

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 Form code in Opitz system for rotational parts in cl a sses
3, and 4

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Supplemental code in Opitz
system

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The OPITZ classification
system
Example: A part coded 20801
2 - Parts has L/D ratio >= 3
0 - No shape element (external shape elements)
8 - Operating thread
0 - No surface machining
1 - Part is axial

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The OPITZ classification
system
Example

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The OPITZ classification
system
Example: Given the part design shown define the
"form code" using the Opitz system
Step 1: The total length of the part is 1.75, overall
diameter 1.25, L/D = 1.4 (code 1)
Step 2: External shape - a rotational part that is
stepped on both with one thread (code 5)
Step 3: Internal shape - a through hole (code 1)
Step 4: By examining the drawing of the part (code 0)
Step 5: No auxiliary holes and gear teeth (code 0)
Code: 15100 47
Group
Technology
SELECTION OF CLASSIFICATION AND CODING SYSTEMS

For the purpose of selecting or developing your own

code, it is important to understand the attributes of
classification and coding systems.

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CELLULAR
MANUFACTURING
Cellular manufacturing is an application of group
technology in manufacturing, in which all or a
portion of a firm’s manufacturing system has been
converted into cells.

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CELLULAR
MANUFACTURING
A manufacturing cell is a cluster of machines or
processes located in close proximity and dedicated to
the manufacture of a family of parts.
The parts are similar in their processing
operations, tolerances and
requirements, such as
machine tool capacities.

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CELLULAR
MANUFACTURING
The primary objectives in implementing a
cellular manufacturing system are to reduce:
Setup times (by using part family tooling and
sequencing)
Flow times (by reducing setup and move
times and wait time for moves and using
smaller batch sizes)
Reduce inventories
Market response times

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CELLULAR
MANUFACTURING
Functional and Cellular layouts of an electronics plant:

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CELLULAR
MANUFACTURING

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Cell
Design
Design of cellular manufacturing system is a
complex exercise with broad implications for an
organization.
The cell designprocess involves issues relatedto
both
System structure and System operation.

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Evaluation of Cell Design
Decisions
The evaluation of design decisions can be categorized
as related to either
the system structure
or
the system operation.

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 Typical considerations related to the system
structure
include:

Equipment and tooling investment (low)

Equipment relocation cost (low)
Material handling costs (low)
Floor space requirements (low)
Extent to which parts are completed in a cell (high)
Flexibility (high)

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The system
operation
Evaluations of cell system design are incomplete
unless they relate to the operation of the system.
A few typical performancevariables related
to
system operation are:
Equipment utilization (high)
Work-in-process inventory (low)
Queue lengths at each workstation (short)
Job throughput time (short) 57
Cell
Design
major problem throughout thecell design
A
process is the necessity of trading off against each
other objectives related to structural parameters
and performance variables.
For example, higher machine utilization can be
achieved if several cells route their parts through
the same machine. The drawbacks are increased
queuing and control problems.

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Cell
Design
System cost and performance are affected by every
decision related to system structure and system
operation.

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CELL FORMATION
APPROACHES
Machine - Component Group Analysis:
Machine - Component GroupAnalysis is
based on production flow analysis
Production flow analysis involves four stages:

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 Production flow
analysis
Stage 1: Machine classification.

Machines are classified on the basis of operations that can

be performed on them. A machine type number is
assigned to machines capable of performing similar
operations.

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Production flow
analysis and
Stage 2: Checking parts list
route information. production

For each part, information on the operations to be

undertaken and the machines required to perform
each of these operations is checked thoroughly.

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Production flow
analysis
Stage 3:Factory flow analysis.

This involves a micro-level examination of flow of

components through machines. This, in turn, allows
the problem to be decomposed into a number of
machine-component groups.

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Production flow
analysis
Stage 4:Machine-component group analysis.
An intuitive manual method is suggested to
manipulate the matrix to form cells. However, as the
problem size becomes large, the manual approach
does not work. Therefore, there is a need to develop
analytical approaches to handle large problems
systematically.

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 EXAMPL
E:
Consider a problem of 4 machines and 6 parts. Try to
group them.

Components
Machine 1 2 3 4 5 6
s
M1 1 1 1
M2 1 1 1
M3 1 1 1
M4 1 1 1

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 Component
s
Machine 2 4 6 1 3 5
s
M1 1 1 1

M2 1 1 1

M3 1 1 1

M4 1 1 1

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Quantitative Analysis in Cellular Manufacturing

Rank Order Clustering Algorithm:

Rank Order Clustering Algorithm is a simple
algorithm used to form machine-part groups.

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Rank Order Clustering
Algorithm
Step 1: Assign binary weight and calculate a decimal weight for
each row and column using the following formulas:

m
Decimal weight for row i = ∑ bip
p=1 2
m-p

n
Decimal weight for column j ∑ bpj n− p

= p=1 2

Where “i” is row no.; “j” is column number; m is number of

columns; n is number of rows; p is the component/part row or
column number
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Step 2: Rank the rows in order of decreasing decimal
weight values.
Step 3: Repeat steps 1 and 2 for each column.
Step 4: Continue preceding steps until there is no change
in the position of each element in the row and the
column.

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EXAMPLE: Consider a problem of 5 machines and 10
parts. Try to group them by using Rank Order Clustering
Algorithm. Components

Machines 1 2 3 4 5 6 7 8 9 10

M1 1 1 1 1 1 1 1 1 1

M2 1 1 1 1 1

M3 1 1 1 1

M4 1 1 1 1 1 1

M5 1 1 1 1 1 1 1 1

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 Binary weight

9 8 7 6 5 4 3 2 1 0
2 2 2 2 2 2 2 2 2 2

Components
Machines 1 2 3 4 5 6 7 8 9 10 Decimal
equivalent
M1 1 1 1 1 1 1 1 1 1
1007
M2 1 1 1 1 1
451
M3 1 1 1 1
568
M4 1 1 1 1 1 1
455
M5 1 1 1 1 1 1 1 1
1020
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 Binary weight

9 8 7 6 5 4 3 2 1 0
2 2 2 2 2 22 2 2 2

Components
Binary Machines 1 2 3 4 5 6 7 8 9 10
weight
4
M5 1 1 1 1 1 1 1 1
2 M1 1 1 1 1 1 1 1 1 1
3
2 M3 1 1 1 1
2 M4 1 1 1 1 1 1
2
M2 1 1 1 1 1
1
2 28 27 27 27 28 20 28 26 11 11
0
2
Decimal
equivalent 72
 Binary weight

9 8 7 6 5 4 3 2 1 0
2 2 2 2 2 2 2 2 2 2

Components

Binary Machines 1 5 7 2 3 4 8 6 9 10 Decimal

weight equivalent

4 M5 1 1 1 1 1 1 1 1 1020
2
M1 1 1 1 1 1 1 1 1 1 1019
3
2 M3 1 1 1 1 900
2
2 M4 1 1 1 1 1 1 123
1 M2 1 1 1 1 1 115
2
28 28 28 27 27 27 26 20 11 11
0
2
Decimal
equivalent 73
Solve using Rank Order Clustering
Technique
Components

Machines 1 2 3 4 5 6 7 8 9

M1 1 1 1
M2 1 1
M3 1 1 1
M4 1 1
M5 1 1
M6 1 1
M7 1 1 1

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