Planning Manufacturing Cells - Society of Manufacturing Engineers

Planning Manufacturing Cells

H. Lee Hales Bruce Andersen

Society of Manufacturing Engineers Dearborn, Michigan

Chapter Three: Input Data and Classification of PParts arts

Copyright © 2002 Richard Muther & Associates No part of this book may be reproduced or transmitted in any form or by any means, including photocopying, recording, or by any information storage and retrieval system, without written permission of Richard Muther & Associates and the publisher. The working forms in the last section of this book are excepted. These may be reproduced for in-company use only, provided that they are reproduced in their entirety so that the name Richard Muther & Associates and the form number appear on all copies. These forms may also be obtained electronically from the authors at www.hpcinc.com/rma.html. Acknowledgment: Portions of this book are adapted from the previously copyrighted works of Richard Muther and Richard Muther & Associates and are included by permission of the authors. Library of Congress Catalog Card Number: 2002103331 International Standard Book Number: 0-87263-549-X Additional copies may be obtained by contacting: Society of Manufacturing Engineers Customer Service One SME Drive, P.O. Box 930 Dearborn, Michigan 48121 1-800-733-4763 www.sme.org SME staff who participated in producing this book: Michael McLelland, Staff Editor Rosemary Csizmadia, Production Supervisor Kathye Quirk, Graphic Designer Frances Kania, Production Assistant Printed in the United States of America

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Dedication This book on manufacturing cells and their planning would not be possible without the prior developments and contributions of three individuals. This book is respectfully dedicated to them: Richard Muther Charles H. Cowles William E. Fillmore The methodology presented in this book — Systematic Planning of Manufacturing Cells (SPMC)—was conceived and first published by Richard Muther. It builds upon his prior developments of Systematic Layout Planning (SLP), Systematic Handling Analysis (SHA), and Systematic Planning of Industrial Facilities (SPIF). Much of the text and many of the illustrations in this book are taken from Richard Muther’s more than 60 years of research, writings, and teaching on cells and other forms of industrial organization. Long-time followers and practitioners of these Muther methods will recognize that even the format of this text is adapted from his pioneering work. Chuck Cowles, for many years a Principal of Richard Muther & Associates, contributed


to early development and assured comprehensive attention to the managerial aspects of cells—those involving operating procedures, operator involvement, and work teams. Several of the examples in this text were developed by Chuck Cowles as a consultant to cell planners. Bill Fillmore has taught thousands of engineers, managers, and shop floor personnel how to plan and implement successful manufacturing cells. Mr. Fillmore co-developed the methodology of Systematic Planning of Manufacturing Cells (SPMC) and its simplified, short-form approach included in this text. He also contributed many of the examples and illustrations based on his extensive work with the clients of Richard Muther & Associates. Many others contributed to the development of SPMC. Special appreciation goes to the members of the Institute of High Performance Planners (IHPP) who reviewed and helped to revise early versions, and to the many clients of Richard Muther & Associates whose cell planning projects formed the basis for the examples and instructions in this book.

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Acknowledgments This text, its companion workbook, and videotapes are by-products of our industrial management services. As such, they rest on our consulting experience in more than 1,000 factories around the world. Each example, illustration, and case problem is drawn from a real situation in industry. So our first debt is to our many clients for the instructive examples they have provided us over the past 45 years. We owe special thanks to: AlliedBendix, Blue Bird Bus, Cummins Engine, Delphi Automotive, Labconco, Metaldyne Sintered Products, and the Taylor Company. These companies have given us especially useful examples and, in several cases, early opportunities to validate our methods and instructional materials. As trainers and workshop leaders, we have had the good fortune and honor to interact with thousands of managers, engineers, and factory workers in more than 20 countries. Hundreds of workshops and many insightful questions have helped us to refine our case examples and target critical issues. For this opportunity, we are grateful to the sponsors of our public workshops. We give special thanks to the Society of Manufacturing Engineers for 10 years of support, and to the University of Wisconsin–Milwaukee, where the Center for Continuing Engineering Edu-

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cation has been hosting cell planning and lean manufacturing workshops for more than a decade. The Material Handling Institute has provided invaluable opportunities to refine our instruction on the material handling and ergonomic aspects of cells. We thank the staff of the Society of Manufacturing Engineers for their invaluable contributions, tireless efforts, and patience in completing this work. Special thanks go to Karen Wilhelm, who gave us the opportunity to write a text and workbook, and to Bob King, who patiently supported the effort to completion. Mike McLelland helped engineers become effective writers, and Kathye Quirk worked her magic on more than 100 illustrations, making them attractive, consistent, and instructive. Steve Bollinger took our written procedures and brought them life in a compelling and highly-instructive video program. Finally, we thank our families for tolerating many absent evenings, weekends, and holidays. H. Lee Hales President Bruce Andersen Senior Associate Richard Muther & Associates



About the Authors H. Lee Hales

Bruce J. Andersen, CPIM

President, Richard Muther & Associates. Founder, High Performance Concepts, Inc. Author or co-author of the books and videos entitled Computer-aided Facilities Planning, CIMPLAN, Systematic Planning of Industrial Facilities, Fundamentals of Plant Floor Layout, and Fundamentals of Manufacturing Cell Planning.

Manufacturing and facilities consultant with Richard Muther & Associates. Former production engineer, instructor, and contributor on cell planning to Maynard’s Industrial Engineering Handbook. Co-author of the video Fundamentals of Manufacturing Cell Planning.


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Table of Contents Preface .................................................................................................................... xiii reface.................................................................................................................... PART ONE 1 Introduction to Manufacturing Cells .................................................................... 1-1 What is a Cell? ....................................................................................................... 1-1 Types of Cells .......................................................................................................... 1-1 The History of Cells ................................................................................................. 1-4 Motivation for Cells ............................................................................................... 1-11 Problems with Cells ............................................................................................... 1-13 The Three Aspects of Cell Planning ........................................................................ 1-15

2 Systematic Planning of Manufacturing Cells (SPMC) ............................................. 2-1 A Universal Approach to Planning ............................................................................ Four Phases of Cell Planning ................................................................................... Levels of Cell Planning ............................................................................................ Three Fundamentals of Cell Planning ....................................................................... Cell Planning Procedures ......................................................................................... SPMC—An Example ................................................................................................

2-1 2-1 2-2 2-4 2-4 2-7

PART TWO 3 Input Data and Classification of PParts arts .................................................................. 3-1 Key Input Data for Cell Planning .............................................................................. 3-1 Obtaining and Recording Key Input Data ................................................................. 3-8 Data Requirements Vary by Project ......................................................................... 3-10 Why and When to Classify ..................................................................................... 3-11 Techniques for Parts Classification and Grouping .................................................... 3-11 General Procedure for Parts Classification .............................................................. 3-13

4 Process Analysis—Equipment and Flow ............................................................... 4-1 Process Charting ..................................................................................................... 4-1 Establishing Equipment and Operator Requirements ................................................. 4-5 Ways to Resolve Capacity and Utilization Problems ................................................. 4-23 Manufacturing Cell Flow Diagrams ........................................................................ 4-25 The Size and Number of Cells ............................................................................... 4-27 Planning Manufacturing Cells

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5 Cell LLayout ayout Planning .......................................................................................... 5-1 Cell Location Within the Plant .................................................................................. 5-1 Objectives of Cellular Layout ................................................................................... 5-1 Basic Cell Flow Patterns ........................................................................................... 5-2 Influence of Material Handling Methods ................................................................... 5-6 Communications and Controls .............................................................................. 5-11 Supporting Services and Equipment ....................................................................... 5-13 Multi-cell Layouts .................................................................................................. 5-13 Flexibility, Adaptability, and Versatility ..................................................................... 5-15 Characteristics of Lean Cell Layout ......................................................................... 5-17 How to Prepare an Overall Cell Layout ................................................................... 5-18

6 Cell Operating PProcedures rocedures ................................................................................. 6-1 Single-piece vs. Batch Flow ...................................................................................... 6-1 Cell Specific vs. Standard and Plant-wide Procedures ................................................ 6-3 Quality Assurance and Control ................................................................................ 6-3 Engineering Support ................................................................................................ 6-5 Production Reporting ............................................................................................... 6-5 Pull Systems, Scheduling, and Sequencing ................................................................ 6-9 Maintenance Practices and Issues ........................................................................... 6-17 Cost Accounting Practices and Procedures .............................................................. 6-19

7 Personnel and Management Planning ................................................................. 7-1 Leadership and Supervision ..................................................................................... Job and Work Assignments ...................................................................................... Training, Cross-training, and Skill Development ........................................................ Cell Performance Measurement ............................................................................... Compensation and Incentives .................................................................................. Recruiting and Ongoing Staffing ..............................................................................

7-1 7-2 7-3 7-4 7-5 7-7

8 Refinement and Evaluation of Plans .................................................................... 8-1 Modifying and Refining Preliminary Plans ................................................................. 8-1 Cost Factors for Comparison ................................................................................... 8-3 Evaluation of Intangible Factors ............................................................................... 8-4 Phase II—Visualization and Presentation of Alternatives ............................................. 8-9 Selection and Approval ........................................................................................... 8-9 Overlapping Considerations .................................................................................. 8-11

PART THREE 9 Detailed Cell Plans ............................................................................................ 9-1 Confirm Input Data and Parts Classification .............................................................. 9-1 Detailed Routing and Process Analysis ...................................................................... 9-1 Detailed Layout Planning ......................................................................................... 9-7 Operator-machine Interaction and Delay................................................................ 9-13 Enabling Single-piece Flow .................................................................................... 9-13

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Chapter Three: Input Data and Classification Table of Contents of PParts arts

Detailed Procedural Planning ................................................................................. Mistake-proofing Methods ..................................................................................... Visual Communication, Signage, and Control ........................................................ Detailed Personnel Planning .................................................................................. Visualization of Detailed Cell Plans ........................................................................ Viable Alternatives, Selection, and Approval ...........................................................

9-16 9-17 9-18 9-20 9-21 9-24

10 Workplace Design ........................................................................................... 10-1 Principles of Motion Economy and Workplace Design .............................................. 10-2 Procedures for Workplace Design ........................................................................... 10-3 Machine Design for Cells ...................................................................................... 10-8 Ergonomic Assist and Safety Equipment .................................................................. 10-9 Impact of Conveyors on Workplace Design ........................................................... 10-16 Workplace Visual Control .................................................................................... 10-17

PART FOUR 11 Orientation and PProject roject Planning ...................................................................... 11-1 Setting Specific Objectives ..................................................................................... Establishing Cell Location and External Conditions .................................................. Obtaining Support and Involvement ....................................................................... Scope and Form of Output .................................................................................... Project Tasks and Schedule .................................................................................... Planning Issues List ................................................................................................

11-1 11-4 11-4 11-5 11-6 11-6

12 Implementation ............................................................................................... 12-1 Approvals, Funding, and Responsibilities ................................................................ Planning the Implementation ................................................................................. Managing the Implementation ............................................................................... Installing the Cells ................................................................................................. Checks, Follow-ups, and Ongoing Improvement ..................................................... Conclusion ...........................................................................................................

12-1 12-1 12-4 12-6 12-7 12-8

APPENDICES I: Additional TTechniques echniques for Grouping PParts arts ............................................................... I-1 Matrix-based Routing Analysis .................................................................................... I-1 Group Technology Classification and Coding ...........................................................I-10

II: Coupling and Integration W orksheet .................................................................... II-1 Worksheet III: Checklist for Detailed Cell Design and Implementation ....................................... III-1 Detailed Cell Design Checklist ................................................................................. III-1 Cell Installation and Equipment Relocation Checklist ................................................. III-4 Cell Assessment Checklist ........................................................................................ III-4

IV -1 IV:: Special Considerations for Cell Automation ........................................................ IV IV-1 Levels of Automation ............................................................................................... IV-1


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Cell Control Systems ............................................................................................... IV-2 Computer-integrated Manufacturing ........................................................................ IV-3 Computer Simulation .............................................................................................. IV-7 Scope and Complexity ............................................................................................. IV-7 Conditions Favoring Automation .............................................................................. IV-9 Key Planning Issues ................................................................................................. IV-9

V: PProcess rocess Charting ................................................................................................. V-1 Process Chart Symbols ............................................................................................. V-1 Creating an Operation Process Chart ........................................................................ V-1 Creating a Flow Process Chart .................................................................................. V-4

VI: Synopsis of Simplified SPMC .............................................................................. VI-1 Step 1: Orient The Project ........................................................................................ VI-2 Step 2: Classify the Parts .......................................................................................... VI-2 Step 3: Analyze the Process ...................................................................................... VI-2 Step 4: Couple Into Cell Plans ................................................................................. VI-2 Step 5: Select the Best ............................................................................................. VI-3 Step 6: Detail and Implement .................................................................................. VI-3

WORKING FORMS .............................................................................................. WF -1 WF-1 Index ............................................................................................................... index -1 index-1

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Preface This book is written for any person needing to plan or re-plan a manufacturing cell. We expect the typical reader to be a leader or member of a cell planning team. This book will also serve those who must review and approve cell plans made by others. By job title, you may be an engineer, supervisor, manager, assembler, or operator of production equipment. You may work in a supporting function, such as materials management, scheduling, maintenance, quality assurance, or human resources. You may be the leader of a larger improvement program, such as lean manufacturing, just-in-time, or total quality management. Regardless of your specific occupation and prior experience, our goal is the same: to help you become a more effective cell planner. We seek to accomplish this goal by explaining and illustrating a proven, universal approach to planning any type of cell—an approach that addresses not only physical aspects, such as layout, but also operating procedures and personnel management practices. We call this approach Systematic Planning of Manufacturing Cells (SPMC). It has been developed using decades of experience with our clients planning projects. It has also been learned and applied by several thousand attendees of our workshops around the world. All told, we estimate that hundreds and quite likely thousands of cells have been planned using this method. Several companies have standardized their planning upon it. SPMC is not meant as a substitute for judgment or knowledge about specific manufacturing processes. It is not perfect and is still subject to enhancement and refinement in Planning Manufacturing Cells

actual use. SPMC is purposefully not doctrinaire. It does not prescribe a plan, such as Ushaped layout, or specific management policies, such as self-direction by teams or group incentives. Instead, it provides an organized way of identifying and making the most appropriate choices and decisions for a given project situation. SPMC consists of a framework of phases through which each cell plan passes; a pattern of procedures for step-by-step planning; and a set of conventions for identifying, visualizing, and rating the various parts groupings, process flows, and alternative arrangements involved in any project. The phases of SPMC conform to the standard four-phased structure of Richard Muther’s widely used planning methods. This structure, which moves from external to internal and from general to particular, is widely accepted in industrial engineering. The pattern of procedures applies Muther’s high-performance planning model to the specific process of cell planning. The effectiveness of a five-section planning pattern has been proven in Muther’s other methods: Systematic Layout Planning (SLP), Systematic Handling Analysis (SHA), and Systematic Planning of Industrial Facilities (SPIF). The conventions of SPMC are consistent with Muther’s methods and with commonly accepted industrial engineering notation. The symbols and vowel codes are widely recognized throughout the industrial world. However, planners do not have to adopt these conventions to follow the phases and the pattern. In fact, there are times when the SPMC

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Preface Three: Input Data and Classification of PParts Chapter arts

conventions may be modified for special meaning or substituted by others that are more appropriate. This book is intended as an instruction manual or guide. The four parts of this text correspond to the four phases of a typical cellplanning project. The chapters correspond to the steps or procedures to be performed within each phase. The illustrations, checklists, and examples are taken directly from a variety of real projects. The working forms at the rear of this book provide direct, practical assistance to the reader; however, it is the total SPMC package—the complete planning system—that provides the greatest benefit. We know from the experience of our clients and workshop graduates that this system of cell

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planning will enable our readers to implement effective manufacturing cells without prior or formal training as an industrial engineer. The companion workbook provides simple case problems and exercises to help master the planning process prior to beginning a real project. The companion videotapes provide a fast-paced summary of cell planning for general awareness and education. The text, workbook, and video comprise a ready-to-use kit for introducing and expanding the use of cells at your plant. H. Lee Hales Bruce J. Andersen Marietta, Georgia


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Planning Manufacturing Cells - Society of Manufacturing Engineers

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