Lean Manufacturing Techniques - Cellular Manufacturing

Cellular manufacturing is the term applied to the production of components from a group of machines. The use of a cell for component manufacture is one of the essential building blocks of lean manufacturing.

The Importance of One Piece Flow

Cellular manufacturing works on the principle of one-piece flow, in that all of the manufacturing operations within the cell are conducted in a continuous sequence. The key to successful performance of a cellular manufacturing set-up is to reduce the overall production cycle time within the cell to, as near as possible, the sum of the cycle times for the individual operations. Cellular manufacturing will enable the operatives to deliver components significantly more quickly than using the equivalent equipment on batch production set to run on similar cycle times. This improvement is achieved by reducing the time normally lost whilst waiting for the accumulation of WIP between machines, when arranged for batch production.

Variety of Production

Manufacturing cells are invariably designed to enable a number of different part configurations to be processed. Depending on the cycle times and throughput required, cells are also designed for multiple operators, although care has to be taken to balance the process accordingly.

Cellular Manufacturing Machine Layout

Usually the machines allocated to a cell are grouped close together in a U-formation to reduce the travel and reach distances for the operatives and materials. Properly designed cells use space very effectively. Significant space savings can be achieved in a manufacturing plant using multiple cells. Also, because of the close working environment within multi-operator cells, there is an opportunity to improve communication and teamwork.

The Benefits of Cellular Manufacturing

Well laid out and balanced manufacturing cells will therefore deliver a number of key benefits, which include:

  • Reduction of WIP
  • Good space utilisation
  • Lead-time reduction
  • Flexibility of product type
  • Good communications and teamwork

Changeover Time Reduction and Zero Defects Initiatives

For maximum benefit, improvements in changeover time for machines and the introduction of zero defects initiatives should be introduced, whenever a cellular manufacturing programme is implemented.