2.810 Version 3; 10/27/04 1TPS Cells and Manufacturing System ComparisonsT. GutowskiRef;n J T. Black Factory with a Future McGraw-Hill 1991, Chapters 2 & 4n“The Monument of Monuments” from Lean Thinking, Womack & Jones 1996n5 homework problems due November 3rd2.810 Version 3; 10/27/04 2Topicsn Operation of cell; Standard workn Increase in production raten Video of cellsn L, λ & W for cell; L=λWn Design of celln Comparison with job shop and flow line2.810 Version 3; 10/27/04 3Cell Featuresn “Synchronized”, sequential productionn Operator decoupled from individual machinesn Operator integrated into all tasksn Goal: single piece Flown Best with single cycle automatics, but can be done manually too2.810 Version 3; 10/27/04 4Machining CellOperator moves part from machine to machine(including “decouplers”)by making traversearound the cell.2.810 Version 3; 10/27/04 5Machining Cell3 + 319F.I.490= 153M+WTotals60315G60320VM270320VM1120312HM50312L270310L160315Saw3RawMachine(Sec)Walk(Sec)Manual(Sec)12345678910Walking segments - 102.810 Version 3; 10/27/04 6Machining Cell3 + 319F.I.490= 153M+WTotals60315G60320VM270320VM1120312HM50312L270310L160315Saw3RawMachine(Sec)Walk(Sec)Manual(Sec)12345678 91011121314Parts in the cell ~ 142.810 Version 3; 10/27/04 7Standard Work for CellPART:JT. Black Cell Operators:PROCESS# OPERATION Man Walk Auto1 Raw 32 Saw 15 3 603 L1 10 3 704 L2 12 3 505 HM 12 3 1206 VM1 20 3 707 VM2 20 3 608 G 15 3 509 F.I. 19 6160 18060 80 100 120TIME {secs}20 40 140Cell produces one part every 153 secNote: machine time Max (MTj) < cycle time CTi.e. 120+12 < 1532.810 Version 3; 10/27/04 880Work 1490= 159M+WTotals3 + 319F.I.79Work 260315G603+320VM270320VM1120312HM50312L2703+310L160315Saw3RawMachine(Sec)Walk(Sec)Manual(Sec)WORKER 1WORKER 2To increase production rate add 2ndworker2.810 Version 3; 10/27/04 9What is the production rate for this new arrangement?Check max(MTj) < CTWorker 1; 80 = 80Worker 2; 12+120 >79One part every 132 secondsCan we shift work off of the HM to reduce the cycle time?2.810 Version 3; 10/27/04 1080Work 1490= 159M+WTotals3 + 319F.I.79Work 260315G60903+320VM27080320VM112080312HM50312L2703+310L160315Saw3RawMachine(Sec)Walk(Sec)Manual(Sec)WORKER 1WORKER 22.810 Version 3; 10/27/04 11Standard Work for Worker #2Rod Support Operators: Worker #2PROCESSOPERATION Man Walk Autofrom decoupler 1.5L2 12 3 50HM 12 3 80VM1 20 3 80VM2 20 1.5 90160 18060 80 100 120TIME {secs}20 40 140Cycle # 1 Cycle # 2Operator waitingOn machine+32.810 Version 3; 10/27/04 12What is the new production Rate?Check max(MTj) < CTWorker 1; 80 = 80Worker 2; 110 > 79Hence Worker #2 will be waiting on Vertical Mill #22.810 Version 3; 10/27/04 13What is the new production Rate?n The new production rate is;one part every 110 secn Pro and Cons; Worker “idle”, can’t speed up by adding additional workern Design for flexibility make;Max(MTj) < CT/22.810 Version 3; 10/27/04 1480Work 1490= 159M+WTotals3 + 319F.I.79Work 260315G603+320VM270320VM1120312HM50312L2703+310L160315Saw3RawMachine(Sec)Walk(Sec)Manual(Sec)WORKER 1WORKER 2A BAlternative solution add 2 HM’s2.810 Version 3; 10/27/04 15Would you like the job of cell operator? Seeta cave, Ellora, IndiaSee B&S Video2.810 Version 3; 10/27/04 16TPS Cell and Little’s Lawn L =λ W, we know L and λ, what is W?n Define System Boundariesn Follow part around the celln Single operator case2.810 Version 3; 10/27/04 17Machining Cell12345678 910111213Number of round trips; 13153X13=1989150out19+3Manual and walk+1531.5+15Grind…….…….+1531.5+ 10L1+1531.5#1 decoupler+ 1533+15Saw1989 + 150 = 21392.810 Version 3; 10/27/04 18By Little’s LawL = (13 + 1) X (150/153) +13 X (3/153) = 13.98rate, λ = 1/153W = 153 X 13.98 = 2139Homework #1Determine L,λ & WFor the 2 operator Systems2.810 Version 3; 10/27/04 19Designing a cell for the “Rod Support”Goal one part every 2.5 minutesn Material; Aluminum extrusionn Tolerance + 0.005”, except for the two 0.50” radius corners which have + 1/64”2.810 Version 3; 10/27/04 20Cellular Layout (One operator)Cold Saw Radial Arm Drill PressDrill PressBelt Sander2.810 Version 3; 10/27/04 21Cellular Layout (One operator)# MachineOperation (V = volume, A=Area, P = perimeter)FixtureTool ChangeRun (R= rough, F = finish)Deburr, Inspect, Measure (Time)Manual TimeMachine Time20Radial Arm Drill Press1" Rad half hole use hole cutter0.12 0 0.24 0.35 0.47 0.2430 Drill Press 1" dia from drill 0.12 0 0.04 0.43 0.55 0.040.200.10.270.200.10.10.10.720.4Sand 2*0.5" radBelt Sander40 0.80.32 0 0.72 010 Cold SawSaw extrusion to 4", A=2, P=9 without D+I+M0.32 Note; Times in minutes2.810 Version 3; 10/27/04 22Cellular Layout (One operator)RA Drill Press .47+.05/.24Cold Saw .32+.05/.72Drill Press .55+.05/.04Belt Sander .8+.05/.4Walking timemanualNote: times in minutesWalking Time 0.2Total Manual Time 2.34Max Machine Time 0.72Cycle Time 2.342.810 Version 3; 10/27/04 23Standard Work forRod Support CellPART: Rod SupportOperators:PROCESS# OPERATION Man Walk Auto1 Extrusion 32 Cold Saw 19 3 433 Rad Arm Drill Press 28 3 144 Drill Press 33 3 25 Belt Sander 48 3 016060 80 100 120TIME {secs}20 40 140Note; Times in Seconds2.810 Version 3; 10/27/04 242.810 Homework; #2 Increase the production rate for this cell to one part every minute#3 After reading “The Monuments of Monuments”, answer;a) Calculate the production rate for each systemb) How many cells are required to replace the Blohm grinder?2.810 Version 3; 10/27/04 25Other LayoutsJob ShopFlow LineFMS2.810 Version 3; 10/27/04 26Cost Estimaten Variable Costs – labor and Materialsn Fixed Costs – equipment and auto feedC/NNC = F + V N2.810 Version 3; 10/27/04 27Job shop (Small quantities, Aluminum block)# MachineOperation (V = volume, A=Area, P = perimeter)FixtureTool ChangeRun (R= rough, F = finish)Deburr, Inspect, Measure (Time)Deburr, Inspect, Measure0 0.3 Deburr0.05 Inspect0.20 2 0.13 0.63 Deburr0.20 0.75 0.05 Inspect0.13 Measure0.46 0.43 Deburr0.67 0.05 Inspect0.13Measure2.19 0.5 Deburr0.93 0.05 Inspect0.13 Measure0.13 MeasureDrill hole 1" diameter* Center drill*Pilot drill 1/2"20.050.05Inspect*Pilot drill 63/64" 2 0.04 0.17 MeasureReam 2 0.012 0.96 0.24 Deburr0.1 0.05 Inspect0.06 Measure0.2 0.1 Deburr0.05 Inspect0.06 Measure0.06 MeasureTotals 1.31 12 8.75 3.6325.693700.2100.08Sand 0.5" radii, V=0.05, A=0.79, P=3.1425060 20.03 0.21 DeburrBore 1" radius, V=0.79, A=1.57, P=7.280.2000.22Mill out 2"*1.5"*4", V=12, A=14, P=15240 0.00 30 2Mill width to 2",
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