GROUP TECHNOLOGY,

CELLULAR MANUFACTURING AND FLEXIBLE

MANUFACTURING SYSTEM (FMS)

Unit V
• Group Technology(GT),Part Families–Parts Classification and coding–
Simple Problems in Opitz Part Coding system–Production flow Analysis–
Cellular Manufacturing–Composite part concept–Types of Flexibility - FMS
– FMS Components – FMS Application & Benefits – FMS Planning and
Control– Quantitative analysis in FMS
Group Technology - Introduction
Define: 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. This group of parts or
components is called part families.
• 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.
• 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.
Where to use
• 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.
What are Part Families?

• It is a collection of part which are similar either because of geometric shape

and size or because similar processing steps are required in their
manufacture.

• The other important features that is important choosing the families:

Manufacturing tolerances, Similar Materials, Special features

EXAMPLE:

THIRTEEN PARTS WITH SIMILAR MANUFACTURING

PROCESS REQUIREMENTS BUT DIFFERENT
DESIGN ATTRIBUTES
 FUNCTIONAL LAYOUTS ARE INEFFICIENT

Lathe Milling Drilling

L L M M D D

D D
L L M M
Grinding
L L M M G G

Assembly
L L G G
A A
Receiving and A A G G
Shipping

PROCESS-TYPE LAYOUT
 GROUP TECHNOLOGY LAYOUT

L L M D G

A A
Receiving L M G G

L M D Shipping
 CELLULAR LAYOUT
Department #2 Department #1

D D M I D
I
L
Department #3
M
M
L L D M I
Benefits of GT
•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.
TYPES OF CLASSIFICATION AND CODING SYSTEMS

GT CODING CAN BENEFIT MANY FACETS OF THE

FIRM AND FALL INTO ONE OF 3 CATEGORIES:

1. SYSTEMS BASED ON PART DESIGN

ATTRIBUTES
2. SYSTEMS BASED ON PART MFG.
ATTRIBUTES
3. SYSTEMS BASED ON DESIGN AND MFG.
ATTRIBUTES
 Examples of Part Families

Dissimilar Parts , Similar Operations

Similar Parts , Similar Operations

Identical Parts, Diff. Manufacturing Process Parts grouped by geometric shape

Methods of grouping Part Families
Visual Inspection Method
 Production flow analysis (PFA)

• PFA is a method of identifying part families and associated machine tool grouping by analyzing
the route sheets for parts produced in a given shop.
• It group together the parts that have similar operation sequences and machine routings.
PFA Matrix
Parts Classification and Coding
 Monocode or Hierarchical code
 The structure of monocode is like a tree in which each symbol amplifies the information provided in
the previous digit.

 It provides a relatively compact structure which give information about part in a limited no. of digits.
 Polycode (Chain type)

The code symbols are independent of each symbol in the sequence is fixed and not depend on the
preceding digit.
Each digit in specific location of the code describes a unique property of the work piece
 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
 MIXED CODE (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.
A code created by this manner would be relatively more compact than a pure attribute code while
retaining the ability to easily identify parts with specific characteristics.
Parts Classification and Coding Systems
 The OPITZ classification system

It is a mixed (hybrid) coding system

Developed by Opitz, Technical University of Aachen, 1970
It is widely used in industries and 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
It considers both design and manufacturing information
OPITZ classification system
MICLASS System
DCLASS Coding System
 BENEFITS OF GROUP TECHNOLOGY

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

2. Layout planning
• Reduction in production floor space required
• Reduced material-handling effort

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
 BENEFITS OF GROUP TECHNOLOGY

4. Manufacturing: process planning 6. Manufacturing: quality control

• Reduction in setup time and production • Reduction in number of defects leading to reduced inspection
time effort
• Alternative routing leading to improved • Reduced scrap generation
part routing • Better output quality
• Reduction in number of machining
operations and numerical control (NC) 7. Purchasing
programming time • Coding of purchased part leading to standardized rules for
purchasing
5. Manufacturing: production control • Economies in purchasing possible because of accurate
• Reduced work-in-process inventory knowledge of raw
• Easy identification of bottlenecks material requirements
• Improved material flow and reduced • Simplified vendor evaluation procedures leading to just-in-time
warehousing costs purchasing
• Improved usage of jigs, fixtures, pallets,
tools, material handling, and 8. Customer service
manufacturing equipment • Accurate and faster cost estimates
• Efficient spare parts management, leading to better customer
service.