The topic of what is cellular manufacturing and its various aspects must be understood to streamline assembly line manufacturing. It is a popular process combining diverse processes in the product line, and it unifies and simplifies the manufacturing unit. With this manufacturing system, the inventory costs and set-up lines can be reduced significantly. Explore more about what is cellular manufacturing in this comprehensive blog.
What Is Cellular Manufacturing?
Cellular manufacturing is a manufacturing system where various production processes are coordinated into individual units allotted to a particular component or part of the production system. It is the mechanism involving utilizing multiple cells in an assembly line fashion.
The individual cells comprise a single machine or multiple machines that work as a single unit. The concept of cellular manufacturing groups similar operations and actions together to minimize unusable and less productive cell movements. The cells are designed in a 'U-shape' that allows the business owner to watch over the entire process efficiently.
Cellular manufacturing is a composite structure that combines the benefits of a product production line and job location to ensure a continuous flow.
Cellular Manufacturing vs. Traditional Layouts
Cellular manufacturing is a modern and hybrid method. However, there are traditional layouts also used in the manufacturing sector. Here are some distinctions between cellular and traditional layouts:
Cellular manufacturing improves resource utilization and flexibility by assembling similar techniques, leading to quicker product cycle times. But, traditional layouts require more resources and amenities to handle various techniques.
Cellular manufacturing allows the efficient flow of materials and machines with little or no additional workforce or equipment movement. Traditional layouts can result in longer wait times and higher transportation costs because they require constant movement of materials and machines throughout the facility.
Cellular manufacturing reduces setup times and scrap rates, whereas traditional layouts can lead to higher inventory levels as each process requires its inventory.
Benefits of Cellular Manufacturing
Cellular manufacturing can profit businesses and customers by increasing productivity, improving quality, lowering costs, and reducing lead times for businesses. It is advantageous for the customers as there is an enhancement in product quality, availability, and faster delivery time.
The system maximizes profit and offers better working conditions, effective workflow, and a centralized production line, providing a better working experience for the workers. A positive work environment reinforces the performance of the employees and ultimately enhances the profits and overall revenue of the company.
Here are some of the other benefits of cellular manufacturing discussed below:
Increased efficiency and productivity
Cellular manufacturing reduces the time spent on each task, allowing for more efficient production. It is done by allocating multiple production tasks into manageable units. Cellular manufacturing firms have improved performance, like reduced work-in-process, lead time, late orders, scrap, direct labor, and workspace.
Reduced lead times and costs
Cellular manufacturing reduces costs by decreasing the time spent on each task and quickly producing smaller batches of products, resulting in lower production costs. In this way, cellular manufacturing reduces lead times by streamlining assembly processes and reducing set-up times.
Improved quality control
Cellular manufacturing improves product quality by reducing production times and streamlining operations, allowing production lines to focus on the quality of each product.
Enhanced flexibility in production
Cellular manufacturing enables businesses to use various product types and features on the production line, reducing the time it takes for a single product to flow through the process. It enhances the flexibility and production processes of the company.
Reduced work-in-progress inventory
The inventory of raw materials and finished products at various stages of the manufacturing process is known as work-in-progress. Reduced setup times can cut the amount of work in progress by half.
Disadvantages of Cellular Manufacturing
Here are the disadvantages of cellular manufacturing units in companies;
High-setup costs: The initial cost of establishing a cellular manufacturing system can be high due to the need for new equipment, technology, and worker training. Difficulty in monitoring: Due to the various locations, cellular manufacturing systems are challenging to monitor and control, making it challenging to track progress and recognize possible pitfalls. Restricted flexibility: Cellular manufacturing systems may limit flexibility and adaptation to changing market conditions. Complex logistics: Cellular manufacturing requires complex logistics due to moving parts, equipment, and materials between manufacturing cells.
Cellular Manufacturing Layouts
It is a physical organization and amalgamation operated within a company that deals with developing work cells, i.e., small units including 3-12 workers. It is crucial for enhanced work productivity, efficiency, and product production.
The cellular manufacturing strategy for a company is to supplement the employees and labor with all the equipment and required machinery, and supplies on demand without delaying and wasting time on sourcing them.
The cellular manufacturing layout does not have a fixed size. It can be small, comprising up to three workers or as many as a dozen workers with one or multiple types of machinery required. The strength of the layout depends on the type of company, needs, and size of the company.
The companies can lead various sizes and formats for the cell design to cater to their functionality, productivity, work balance, and more.
Here are the essential cellular manufacturing layouts that businesses use:
U-Shaped cells: They are among the most popular cell formations. It is perfect for companies looking to maximize the space on their modeling floor and requires the least space. It is commonly used for a manufacturing or assembly cell where workers stand or walk to conduct the operations. I-shaped cells: In this method, the companies can maximize productivity by coordinating the resources and equipment closely to produce the maximum results. It is ideal for businesses with thin and long physical assembly spaces. O-Shaped cells: These are similar to a U-shaped cell with machines arranged in a rough circle that a single technician oversees. It is appropriate for products that require multiple machine passes. L-Shaped cells: The L-shaped cells are perfect for square buildings and are used in most warehouses. They connect vital processes, equipment, and resources to increase efficiency while reducing excessive waste.
Implementation of Cellular Manufacturing
Cellular manufacturing is a lean inventory concept and the company must understand and adapt the ideologies and information of the lean manufacturing principles. Cellular manufacturing is a powerful concept and requires 100% input from the employees and the business manager.
A successful implementation increases customer satisfaction, improves the profits of businesses, and enhances customer satisfaction due to faster delivery and high product quality.
The following steps are involved in the development of cellular manufacturing:
- Access the production environment and develop a steady flow
- Identify and design the production cells
- Group the machinery into operating cells
- Develop a process flow
- Allocate resources and equipment
- Monitor the performance and make desired changes
Here is a step-by-step guide and other crucial details to implement cellular manufacturing:
Building a culture of continuous improvement
The first step in cellular manufacturing is to evaluate the production environment and identify the manufacturing processes and materials that will be used. To transport WIP between operations, measure time elements such as cycle time, and lead time. Evaluate the portability and flexibility of machines, equipment, and workstations, and mock up a single manufacturing cell to assess feasibility and performance. The key is to promote a culture of continuous improvement. To develop a continuous flow, businesses must understand their customers' needs and product expectations.
Identifying product families and their flow paths
The product families and cells that produce similar products or parts and the type of cell determine which products or product families will go into them. It can be further utilized to enhance the product flow. Choosing the quantity and type of machinery required is a necessary step in designing production cells. It includes deciding on factors such as size, location, and layout of each cell.
Grouping machines and operators into cells
Similar products or those with the same operations work together. Identifying the product families enhances the efficiency of the process. Capture work elements and time needed for each step individually, use the lowest repeatable time and consider machine downtime, and changeover time.
Designing and implementing the layout of the cells
The design of production cells, including the size and location of each cell, and the layout of the machines within each cell is the most important step in producing a successful cellular manufacturing system. Examine the various cell layouts and choose the one that works best for your company. Creating a process flow chart to outline the steps and processes to create excellent products is crucial.
Training and empowering workers
The process flow chart must be created to assign resources to each production cell and monitor and analyze performance. It allows the elements of production to work efficiently. It includes assigning personnel, machines, tools, and materials to each cell and monitoring and analyzing performance. Once the personnel is trained, the company can assign the resources efficiently and cut down on time wastage. The workers or laborers must be taught and trained to initiate a successful cellular manufacturing system. It also facilitates easy monitoring and analyzing of the system without fail.
Challenges and Risks
Cellular manufacturing is popular among companies. However, it is key to note that it has difficulties and challenges. Different organizations must check the investment-to-profit ratio to determine the value of cellular manufacturing for them.
Some challenges and risks are discussed below:
Initial investment costs
The initial cost of establishing a cellular manufacturing system can be high due to the need for new equipment, technology, and worker training. Costs can rise if the system is improperly maintained, resulting in inefficiencies and downtime.
Resistance to change from employee
Labor costs can be high, and businesses must factor in the cost of training and implementing new systems and processes. Cellular manufacturing requires more coordination between multiple workstations, making it difficult to comply with regulations. Changing market trends due to changing consumer demand require employees to change their operations. The absence of it can lead to the failure of the system.
Difficulty in identifying product families and flow paths
It is necessary to identify product families to allot the operations and diverse functions. Different work cells may sometimes require the same machines and tools, resulting in duplication, higher investment in equipment, and lower machine utilization. Product design and automated processing of the product families and cells can solve this concern.
Risk of underestimating the capacity of the cells
Cells are highly dependent on equipment, tools, and machinery. So, equipment failure can hamper the flow and increase the chance of downtime. Investment should be made in maintenance, repairs, and backup equipment to reduce downtime and improve cell flow.
Risk of overestimating the benefits of cellular manufacturing
Businesses can overestimate the system's benefits. However, maintaining the system requires the companies to stay updated with technological advancements, changing trends, new machinery, and products to keep up with the system.
Future of Cellular Manufacturing
Cellular manufacturing is the future of the manufacturing industry. Here are some arguments for why cellular manufacturing is the future:
Advancements in technology and automation
Digitization of manufacturing processes improves productivity and efficiency, as the state of the product is recorded in real-time and can be sent to sales teams or manufacturing teams for renovation. Manufacturing industries are using technological advancements in their endeavors, which will benefit cellular manufacturing.
The increased importance of sustainability in manufacturing
Sustainable plants are better suited to meet regulations, lowering the compliance burden and audit risk. Companies can lower costs and increase profit margins by reducing waste and improving energy, water, and raw material use. As the need for sustainability is rising in the manufacturing sector, the benefits of cellular manufacturing are increasing manifold.
Potential for cellular manufacturing to become the standard for production
It can develop as the standard of production as it eliminates overproduction that impacts the surroundings in multiple ways. It reduces the production that must be discarded as waste and reduction in raw materials, energy, wastes, and emissions generated via unneeded output.
Enable Streamlined Cellular Manufacturing With TranZact
Cellular manufacturing has a significant usage in the future with its ability to enhance efficiency and workforce. Cellular manufacturing combines lean manufacturing with automation to give businesses a competitive advantage in today's global marketplace.
TranZact is a business automation solution that facilitates easy monitoring of all activities related to cellular manufacturing and testing. It enables business teams to record the various stages of production with ease and accelerate finished goods manufacturing effortlessly.
FAQs on Cellular Manufacturing
1. What is the difference between cellular manufacturing and traditional manufacturing?
Cellular manufacturing increases resource utilization by grouping similar processes for faster product cycle times. Traditional layouts require more production facilities and resources.
2. What types of companies can benefit from cellular manufacturing?
Automobiles, appliances, electronics, pharmaceuticals, and several other types of companies can benefit from cellular manufacturing.
3. Is cellular manufacturing only suitable for high-volume production?
No, cellular manufacturing can also be used for small lot production where the equipment and resources can be utilized properly.
