Cellular Manufacturing Tiffany Dundon Boise State University

What will be Covered DefinitionDefinition BrainstormingBrainstorming Nuts and BoltsNuts and Bolts Reported Benefits of Cellular ManufacturingReported Benefits of Cellular Manufacturing How It WorksHow It Works Examples of Cellular ManufacturingExamples of Cellular Manufacturing An ExerciseAn Exercise ConclusionConclusion

Cellular Manufacturing (CM) Defined “ Cellular Manufacturing organizes the entire process for similar products into a group of team members, includes all the necessary equipment and is known as a "Cell". Merryman, Wes. Cellular Manufacturing.Online. Internet. Available at Merryman, Wes. Cellular Manufacturing.Online. Internet. Available at

Cellular Manufacturing Defined “…The cells are arranged to easily facilitate all operations. Parts are handed off from operation to operation eliminating setups and unnecessary costs between operations.” Merryman, Wes. Cellular Manufacturing.Online. Internet. Available at

Brainstorming Brainstorm some ideas about cellular manufacturingBrainstorm some ideas about cellular manufacturing How can this tool be used in your organization?How can this tool be used in your organization?

Nuts and Bolts Elimination of wastes by linking stepsElimination of wastes by linking steps –Waste is any resource not adding value to the product being manufactured In a cell, most work stations are close together so that little or no time is required to move partsIn a cell, most work stations are close together so that little or no time is required to move parts

Nuts and Bolts Cell teams are cross trained in cell operationsCell teams are cross trained in cell operations –Continuous improvement –Reduce lead times –Remove waste –Improve quality Product flow is more visibleProduct flow is more visible –Easier control

Nuts and Bolts Primary purpose:Primary purpose: –Reduce cycle time –Reduce inventories Other benefits include:Other benefits include: –Space reduction –Quality improvement –Labor cost reduction –Improved machine utilization

Nuts and Bolts Human resource issues:Human resource issues: –Proper training for operators –Cross functional training –Team building training for operators

Nuts and Bolts Human Resource issues:Human Resource issues: –Supervisors become coaches –Compensation (incentives) –Initial resistance of CM –Cells need support

Reported Benefits of CM Production and Quality Control Cost 80%Production and Quality Control Cost 80% Setup Time 69%Setup Time 69% Throughput time 70%Throughput time 70% Overdue orders 82%Overdue orders 82%

Reported Benefits of CM Raw Materials Inventory 42%Raw Materials Inventory 42% Finished Goods Inventory 60%Finished Goods Inventory 60% Employees Output per unit time 33%Employees Output per unit time 33% Kok, Alvin Lim Hui. Time Based Manufacturing. Journal of Operations Management. 7 July 1999

How it Works Members of the plant team need to be involved in the changesMembers of the plant team need to be involved in the changes Other functions need to be changed:Other functions need to be changed: –Production planning and control –Purchasing –Cost accounting

How it works Where do you begin?Where do you begin? First, define the “cells” by the following criteria:First, define the “cells” by the following criteria: –Processes required –Part numbers and attributes –Market segments / customers –Degree of automation

How it Works Team selection is crucialTeam selection is crucial –Identify important skills needed such as teamwork and leadership skills –Create a process map –Develop a checklist for selecting members

How it Works Match skills to tasksMatch skills to tasks –Create a matrix to define who is best qualified for each task Develop team trust and motivationDevelop team trust and motivation –Manage team morale –Encourage teamwork

Real World Example John Deere Integrated welding work cellsIntegrated welding work cells Utilizes robotic welding processesUtilizes robotic welding processes –Faster weld times –Consistent welds –Endurance

Real World Example John Deere Major benefits of CM:Major benefits of CM: –Switching of welds is simple –Factory has maximum flexibility –Delivers higher quality –Faster delivery

Real World Example Inscape Production divided into highly specialized “cells”Production divided into highly specialized “cells” –Each cell contains equipment, technology and people –Each cell can make a wide variety of family products

Real World Example Inscape Major benefits of CM:Major benefits of CM: –Consistently high quality –Flexibility for customers –Quick changes in size and style –Mass customization

A Short Exercise How is implementing CM useful in your organization?How is implementing CM useful in your organization? How will you define cells? Form teams? Motivate and develop trust? Change functions? Change the plant layout?How will you define cells? Form teams? Motivate and develop trust? Change functions? Change the plant layout?

Summary CM: based on a group of different processes located in close proximity to manufacture similar productsCM: based on a group of different processes located in close proximity to manufacture similar products You must first define the “cells” and then develop a teamYou must first define the “cells” and then develop a team

Summary Training and support are key elementsTraining and support are key elements Many reported benefits to switching your organization to cellular manufacturingMany reported benefits to switching your organization to cellular manufacturing –Reduce inventories, and more

References John Deere. State-of-the-art Robotic Welding. Online. Internet. 3 May Available at Inscape Solutions. Cellular Manufacturing. Online. Internet. 29 April Available at Kok, Alvin Lim Hui. Time Based Manufacturing. Journal of Operations Management. 7 July 1999 Merryman, Wes. Cellular Manufacturing.Online. Internet. 15 April Available at Patel, Jay. Cellular Manufacturing. Online. Internet. 10 April Available at