Group

Technology
and Cellular
Manufacturing
21M101, 21M102,
21M104, 21M105,
21M106, 21M109
 CONTENT
• Group technology
• Formation of part families- part classification
• Composite part concept
• Cellular manufacturing
• Coding system
• OPITZ and multi class coding systems

2
 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.
● Group technology emphasizes on part families based
on similarities in design attributes and manufacturing,
therefore GT contributes to the integration of
CAD(Computer Aided Design) and CAM(Computer
Aided Manufacturing).
● The group of similar parts is known as part family
and the group of machineries used to process an
individual part family is known as machine cell.
 Implementing Group Technology(GT)

● There are two major tasks that a company must undertake when it
implements group technology. These tasks represent significant
obstacles to the application of GT.
1. 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 and time consuming task.
2. 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.
 Part Families
● A part family is a collection of parts that are
similar either in geometric shape and size or in
the processing steps required in their
manufacture.
● The parts within a family are different, but their
similarities are close enough to merit their
inclusion as members of the part family.
● Two parts of identical shape and size but
Figure.1
different manufacturing requirements:
(a) 1,000,000 pc/yr, tolerance = ±0.010 in.,
material = 1015 CR steel, nickel plate; and
(b) 100 pc/yr, tolerance = ±0.001 in.,
material = 18-8 stainless steel.
 Part Families
● A family of parts with similar manufacturing
process requirements but different design
attributes. All parts are machined from
cylindrical stock by turning; some parts
require drilling or milling.
● The two parts in Figure.1 are very similar in
terms of geometric design, but quite different
in terms of manufacturing because of
differences in tolerances, production
quantities,and materials.
● The parts shown in Figure.2 constitute a part Figure.2
family in manufacturing, but their different
geometries make them appear quite different
from a design viewpoint.
 Group Technology(GT)

● There are three general methods for solving part

families grouping. All the three are time consuming
and involve the analysis of much of data by properly
trained personnel.
● The three methods are:
1. Visual inspection.
2. Production flow analysis.
3. Parts classification and coding.
1. Visual Inspection Method

● 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.
 Part Families and Machine Groups

Process-type plant layout Group-technology layout.

2.) Production Flow Analysis (PFA)

• Production flow analysis (PFA) is a method for

identifying part families and associated machine
groupings that uses the information contained on
process plans rather than on part drawings.
• Work parts with identical or similar process plans
are classified into part families. These families can
then be used to form logical machine cells in a
group technology layout.
• The procedure in PFA must begin by defining the
scope of the study, which means deciding on the
population of parts to be analyzed.
1. This method makes use of the information contained on route sheets rather than
on part drawings.
2. Work - parts with identical or similar routings are classified into part families.

The procedure of production flow analysis is as follows:

I. Data collection: The data such as part number and operation sequence is
collected from manufacturing data contained in the route sheets.
II. Sorting: The parts are separated and arranged into groups according to similar or
identical routings.
III. Preparation of chart:
a) The chart is a tabulation of the process or machine code numbers for all the parts
of a part family.
b) In this tabulation, the entries are cross marked (X).
c) The cross mark (X) indicates I th part requiring j th machine.
d) If X = 0, there is no processing of the ith part on the jth machine.
3.) Parts classification and Coding

• In parts classification and coding, similarities among parts are

identified, and these similarities are related in a coding system.
• This classification and coding may be carried on the entire list of
parts of a family.
•Two categories of part similarities can be distinguished:
1.) Design attributes, which concerned with part characteristics such
as geometry, size and material.
2.) Manufacturing attributes, which consider the sequence of
processing steps required to make a part.
Reasons for using a classification and coding
system:

1.) 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 exist.
A simple change in an existing part would take much less time than
designing a whole new part from scratch.
2.) 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.
3.) Machine cell design: The part codes can be used to design machine
cells capable of producing all members of a particular part family.
Cellular Manufacturing :
● It 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.
● Cellular Manufacturing is a model for
workplace design, and has become an
integral part of lean manufacturing
systems.
● Cellular Manufacturing takes full
advantage of the similarity between
parts, through standardization and
common processing and groups them
into cell.
Typical objectives in Cellular Manufacturing:

● To shorten manufacturing lead times by reducing

setup, work-part handling, waiting times, and batch sizes.
● To reduce work-in-process inventory. Smaller batch
sizes and shorter lead times reduce work-in-process.
● To improve quality. This is accomplished by allowing
each cell to specialize in producing a smaller number of
different parts. This reduces process variability.
 Typical objectives in Cellular Manufacturing:

● To simplify production scheduling. The similarity

among parts in the family reduces the complexity of
production scheduling. Instead of scheduling parts
through a sequence of machines in a process-type shop
layout, the system simply schedules the parts through the
cell.
● To reduce setup times. This is accomplished by using
group tooling (cutting tools, jigs, and fixtures) that have
been designed to process the part family, rather than part
tooling, which is designed for an individual part. This
reduces the number of individual tools required as well as
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the time to change tooling between parts
Machine Cell Design

Machine cells for part family production can be classified according to the number of
machines and the degree to which the material flow is mechanized between
machines. Four common GT cell configurations are
(1) single-machine cell,
(2) group-machine cell with manual handling,
(3) group-machine cell with semi-integrated handling,
(4) flexible manufacturing cell or flexible manufacturing system
 Single-Machine Cell
● As its name indicates, the single-machine
cell consists of one machine plus supporting
fixtures and tooling. This type of cell can be
applied to work parts whose attributes allow
them to be made on one basic type of
process, such as turning or milling.
● A single machine cell consists of one CNC
machining center combined with a parts
storage system for unattended operation.
● Completed parts are periodically unloaded
from the parts storage unit, and raw
workparts are loaded into it
 Group-machine cell with manual handling

● It is an arrangement of more than one machine used

collectively to produce one or more part families, and there is
no provision for mechanized parts movement between
machines in the cell.
● Instead, the human operators who run the cell perform the
material handling function. The cell is often organized into a
U-shaped layout
 U-shaped layout
● This layout is considered appropriate when there is variation in the
work flow among the parts made in the cell. It also allows the
multifunctional workers in the cell to move easily between machines.
● Other advantages of U-shaped cells in batch-model assembly
applications, compared to a conventional paced assembly line, include
(1) easier changeover from one model to the next,
(2) improved quality,
(3) visual control of work-in-process,
(4) lower initial investment because the cells are simpler and no
powered conveyor is required,
(5) greater worker satisfaction due to job enlargement and
absence of pacing
(6) more flexibility to adjust to increased demand simply by adding
more cells
 Group-machine cell with
semi-integrated handling

● The group-machine cell with semi-integrated

handling uses a mechanized handling
system, such as a conveyor, to move parts
between machines in the cell.
Determining the most appropriate cell layout
(1) Repeat operation, in which a consecutive
operation is carried out on the same machine, so
that the part does not actually move;
(2) In-sequence move, in which the part moves
forward from the current machine to an immediate
neighbor;
(3) Bypassing move, in which the part moves
forward from the current machine to another
machine that is two or more machines ahead;
(4) Backtracking move, in which the part moves
backward from the current machine to another
machine.
Composite Part Concept

In Flexible Manufacturing Systems (FMS),

a composite part concept refers to the idea of
creating a single part by combining multiple
smaller components or elements.

By standardizing these sub-components and assembling them in different configurations,

manufacturers can efficiently produce a variety of parts within the same system, enhancing
flexibility and adaptability to changing production needs.
Composite Part Concept

In general, an individual part in the family will have some of the features that characterize the
family, but not all of them.

A production cell designed for the part family would include those machines required to make
the composite part.

Such a cell would be capable of producing any member of the family.

Composite Part Concept
Composite Part Concept

There are several types of composite part concepts in Flexible Manufacturing Systems:

● Modular Assembly
Assembling pre-manufactured modules or sub-components
● Kit Assembly
Using kits of individual components to create composite parts
● Hybrid Structures
Combining different materials or manufacturing processes
● Additive Manufacturing
Utilizing additive manufacturing techniques like 3D printing
● Composite Materials
Using materials like fiber-reinforced polymers or carbon fiber composites
Composite Part Concept

Applications of Composite part concept:

● Automotive Industry
Production of lightweight and high-strength components
● Aerospace Industry
Manufacturing of complex and durable aircraft parts
● Consumer Goods
Customization of products to meet consumer preferences
● Healthcare
Production of customized medical devices and implants
Composite Part Concept

Benefits of Composite part concept:

● Enhanced Flexibility
Ability to produce diverse parts using common building blocks
● Increased Efficiency
Streamlined production processes and reduced setup times
● Customization
Tailoring parts to specific design requirements
● Cost Savings
Standardization of components and optimized manufacturing processes
Composite Part Concept

Implementations of Composite part concept:

● Design for Manufacturability (DFM) principles for composite parts

● Material Selection
Choosing appropriate materials based on performance requirements
● Production Planning
Optimizing production schedules for composite part manufacturing
● Quality Control
Ensuring consistency and reliability in composite part production
Composite Part Concept

Future Trends and Outlook of Composite part concept:

● Integration of advanced technologies like Artificial Intelligence (AI) and Internet of

Things (IoT) in composite part manufacturing
● Continued innovation in materials and manufacturing processes
● Potential challenges and opportunities in the future of composite part concepts
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