Lab Name: To perform grouping of parts and machines into families and arranging machines in the GT
Cell
Course title: Industrial Facility Design Total Marks: 20
Practical No. 7 Date of experiment performed: ____________
Course teacher/Lab Instructor: Engr. Muhammad Usman Date of marking: ____________
Student Name:__________________________
Marking Evaluation Sheet
Contribut Max. Obtain
Taxonomy
Knowledge components Domain mark ed
level ion s marks
1. Student is aware with
requirement and use of Imitation (P1) 3
apparatus involved in
experiment.
2. Student has conducted the Psychomo
experiment by practicing Manipulate 70%
tor 11
the hands-on skills as per (P2)
instructions.
3. Student has achieved
required accuracy in Precision (P3) -
performance.
4. Student aware of discipline
&safety rules and followed Receiving
2
the rules during (A1)
Affective
experiment. 20%
5. Student has responded
well andcontributed Respond (A2) 2
affectively in form of group
or team.
6. Student has applied
Apply
theoretical knowledge to Cognitive 10% 2
obtain and report the (C3)
results.
Total 20
Normalize
marks out 5
of (5)
Signed by Course teacher/ Lab Instructor
Lab Session 07
1. OBJECTIVE:
To perform grouping of parts and machines into families and arranging machines in the GT Cell
(Short description: Perform grouping of machines and parts into families in Paper craft case
problem and arrange machines of the case problem in GT Cell)
2. APPARATUS
Papers, nuts and bolts,
3. THEORY:
1. QUANTITATIVE TECHNIQUES IN GROUP TECHOLOGY AND CELLULER
MANUFACTURING:
A number of quantitative techniques have been developed to deal with problem areas in group
technology and cellular manufacturing. We consider two problem areas: (1) grouping parts and
machines into families, and (2) arranging machines in a GT Cell. The techniques we describe in
the current section for salving the part and machine grouping problem is Rank Order Clustering
technique and technique for arranging machines in a GT cell is Hollier method II.
2. GROUPING PARTS AND MACHINES BY RANK ORDER CLUSTERING:
The problem addressed here is to determine how machines in an existing plant should be
grouped into machine cells. The problem is the same whether the cells are virtual or formal. It is
basically the problem of identifying part families. By identifying part families, the machines
required in the cell to produce the part family can be properly selected. As previously discussed,
the three basic methods to identify part familiesare (1) visual inspection, (2) parts classification
and coding, and (3) production flowanalysis.
The rank order clustering technique is specifically applicable in production flow analysis. It is an
efficient and easy-to-use algorithm for grouping machines into cells. In a starting part-machine
incidence matrix that might be compiled to document the part routings in a machine shop (or
other job shop), the occupied locations in the matrix are organized in a seemingly random
fashion. Rank order clustering works by reducing the part-machine incidence matrix to a set of
diagonalized blocks that represent part families and associated machine groups. Starting with the
initial part-machine incidence matrix the algorithm consists of the following steps:
1. In each row of the matrix. read the series of ls and 0's (blank entries = 0's) from left to Right as
a binary number. Rank the rows in decreasing value. In case of a tie, rank the rows in the same
order as they appear in the current matrix.
2. Numbering from top to bottom, is the current order of rows the same as the rank order
determined in the previous step? If yes, go to step 7, If no, go to the following step.
3, Reorder the rows in the part-machine incidence matrix by listing them in decreasing rank
order, starting from the top
4. In each column of the matrix. read the series of 1 's and 0's (blank entries = 0's) from top to
bottom as a binary number. Rank the columns in order of decreasing value, In case of a tie. rank
the columns in the same order as they appear in the current matrix.
5. Numbering from left to right, is the current order of columns the same as the rank order
determined in the previous step? If yes. go to step 7. If no, go to the following step.
6. Reorder the columns in the part-machine incidence matrix by listing them in decreasing rank
order, starting with the left column. Go to step 1.
7 Stop
2.1 Example: Rank order Clustering Technique:
Apply the rank order clustering technique to the part-machine incidence matrix given below.
Table 1. PFA or part machine incidence matrix of example problem
SOLUTION:
Step 1 consists of reading the series of 1's and 0's in each row as a binary [Link] have done
this in Table 2 converting the binary value for each row to its decimal equivalent. The values are
then rank ordered in the far right hand column. In step 2. we see that the row order is different
from the starting matrix. We therefore reorder the rows in step 3. In step 4, we read the series of
1's and 0's in each column from top to bottom as a binary number (again we have converted to
the decimal equivalent, and the columns are ranked in order of decreasing value, as shown in
Table [Link] step 5, we see that the column order is different from the preceding matrix.
Proceeding from step 6 back to steps 1 and 2, we see that a reordering of the columns provides a
row order that is in descending value. and the algorithm is concluded (step 7). The final solution
is shown in Table 4.
Table2. First Iteration(Step 1 and Step 2) in Rank Order Clustering Technique Applied to
example
Table3. Second Iteration(Step 3 and Step 4) in Rank Order Clustering Technique Applied to
example
Table4. Final solution of Rank Order Clustering Technique Applied to example
3. Arranging Machines in GT Cell:
After part-machine groupings have been identified by rank order clustering or other method. The
next problem is to organize the machines into the most logical arrangement. We will use one of
the methods suggested by Hollier; Hollier Method 2. This method uses data contained in Form-
To chart.
Hollier Method 2:
This approach is based on the use of From/To ratios formed by summing the total flow from and
to each machine in the cell. The method can he reduced to three steps:
1. Develop the From-To chart from part routing data.. The data contained in the chart indicates
numbers of part moves between the machines (or workstations) in the cell. Moves into and out of
the cell are not included in the chart.
2. Determine the From/To ratio for each machine. This is accomplished by summing up all of the
"From" trips and "To" trips for each machine (or operation). The "From" sum for a machine is
determined by adding the entries in the corresponding row, and the "To" sum is determined by
adding the entries in the corresponding column. For each machine, the From/To ratio is
calculated by taking the "From" sum for each machine and dividing by the respective "To" sum.
3. Arrange machines in order of decreasing From/To ratio. Machines with a high From/To ratio
distribute work to many machines in the cell but receive work from few machines. Conversely,
machines with a low From/To ratio receive more work than they distribute. Therefore, machines
are arranged in order of descending From/To ratio. That is, machines with high ratios are placed
at the beginning of the work flow, and machine, with low ratios are placed at the end of the work
flow. In case of a tie, the machine with the higher "From" value is placed ahead of the machine
with a lower value.
3.1 Example of Arranging Machines in GT Cell:
Suppose that four machines. I, 2.3, and 4 have been identified as belonging in a GT machine cell.
An analysis of 50 parts processed on these machines has been summarized in the from-To chart
of Table 5. Additional information is that 50 parts enter the machine grouping at machine 3, 20
parts leave after processing at machine 1, and 30 parts leave after machine 4. Determine a logical
machine arrangement using Hollier Method 2.
Table 5. Form-To chart for example problem of arranging Machines in GT Cell.
SOLUTION:
Table 6. Form/To sums and Form/To ratios for example problem of arranging Machines in GT
Cell.
Arranging the machines in order of descending From/To ratio, the machines in the cell should be
sequenced as below:
3214
4. PROCEDURE:
4.1 Case Problem:
Three different products are to be made as detailed below.
A. Paper plane making by Paper craft method. Fold A4 paper in defined steps to
make a paper plane.
B. Paper ship making by Paper craft method. Fold A4 paper in defined steps to
make a paper ship.
C. Nuts and bolts assembly. Assemble nut and bolt to make nut bolt assembly.
Consider simplified traditional process layout given below for three products. Assign
each machine name one by one to your group members and arrange them in sequence
of figure 1 for each of three products. Calculate the Production rate of the three
products before and after grouping parts and machines into cells and machines
arrangement in the GT cell.
Figure 1. Traditional process layout of three products for the case problem
4.2 Steps:
Before stating the procedure steps for cell formation calculate production rate of the layout
before improvement given in Figure 1.
1. Time consumed:
2. Production:
3. Production Rate:
STEP 1: Data Collection:
The minimum data needed in the analysis are the part numbers and operation sequence which is
contained in shop document named Route Sheet. Each operation is usually associated with a
particular machine, so determining the operation sequence also determines the machine
sequence. Additional data, such as Lot size, time standards, and annual demand might be useful
for designing machine cells of the required production capacity.
Consider following three routing sheets:
Product A: Paper Plane Routing Sheet
Part name: Paper Plane Part number: 01 Drawing Nr.: XXXXX
Revision Nr.: 01 Date: Planner: Engr. M. Usman
Material: A4 Paper Stock size: As folded Comments:
Operation Nr. Description Machine Speed and Time
Feed
01 Get paper for paper craft Get
02 Fold paper in defined steps Fold
03 Finish the craft by last fold Finish
04 Check the Paper plan crafted Check
05 Dispatch the Paper plan Dispatch
Product B: Paper Ship Routing Sheet
Part name: Paper plane Part number: 01 Drawing Nr.: XXXXX
Revision Nr.: 01 Date: Planner: Engr. M. Usman
Material: A4 Paper Stock size: As folded Comments:
Operation Nr. Description Machine Speed and Time
Feed
01 Get paper for paper craft Get
02 Fold paper in defined steps Fold
03 Finish the craft by last fold Finish
04 Check the Paper ship crafted Check
05 Dispatch the Paper plan Dispatch
Product C: Nut and Bolt Assembly Routing Sheet
Part name: Nut Bolt Assembly Part number: 01 Drawing Nr.: XXXXX
Revision Nr.: 01 Date: Planner: Engr. M. Usman
Material: Nut and Bolt Stock size: As priveded Comments:
Operation Nr. Description Machine Speed and Time
Feed
01 Get nut bolt assembly Get
02 Assemble in defined steps Assemble
03 Check the Assembly Check
04 Dispatch Nut Bolt Assembly Dispatch
STEP 2: Sortation of Process routings:
In this step, the parts are arranged into groups according to the similarity of their process
routings. To facilitate this step, all operations or machines included in the shop are reduced to
code numbers, such as those shown in Table 7. For each part, the operation codes are listed in the
order in which they are performed. A sortation procedure is then used to arrange parts into
"packs," which are groups of parts with identical routings. Some packs may contain only one part
number, indicating the uniqueness of the processing of that part. Other packs will contain many
parts, and these will constitute a part family.
Operation or Machine Code
Get 01
Assemble 02
Check 03
Fold 04
Finish 05
Dispatch 06
Table 7. Possible Code numbers indicating Operation or Machine for sortation in Production
Flow analysis
A = Paper Plane Code = 14536
B = Paper Ship Code = 14536
C = Nut Bolt Assembly Code = 1236
Parts in Pack= A, B, C
STEP 3: PFA chart or Part machine incidence Matrix:
The processes used for each pack are then displayed in a PFA chart or Part machine incidence
Matrix. In this matrix, the entries have a value Xij= l or 0: a value of Xij = 1 indicates that the
corresponding part i requires processing on machine j, and Xi = 0 indicates that no processing of
component i is accomplished on machine j. For clarity of presenting the matrix, the 0's are often
indicated as blank (empty) entries.
Parts
Machine A B C
s
1
2
3
4
5
6
Table 7. Form/To sums and Form/To ratios for example problem of arranging Machines in GT
Cell.
STEP 4: Group parts and machines by Rank order Clustering technique:
In this step group parts and machines by Rank order clustering technique as discussed in detail
earlier.
STEP 5: Arranging Machines in GT Cell:
In this step machines are arranged in GT cell obtained in step 5 by using Hollier method 2 which
is discussed in detail earlier.
STEP 6: Suggest the Cell layout of the GT cell with arranged machines:
Calculate production rate of the layout after improvement as given in your last step; step 6.
1. Time consumed:
2. Production:
3. Production Rate:
Conclusion:
Grouping of parts and machines into families and arranging of machines in the GT Cell is
performed.
EXPERIMENT DOMAIN:
Domains Psychomotor (70%) Affective (20%) Cognitiv
e (10%)
Attributes Realization Conducting Data Data Discipline Team work Apply
of Experiment Collection Analysis (Respond/
(Receivin
Experiment Contribute)
(Act) (Use tool) (Perform) g)
(Awareness)
Taxonomy P1 P2 P2 P2 A1 A2 C3
Level
Student Lab report will consist of following:
Objective:
Apparatus:
Procedure:
Discussion:
Which part families identification method is used in this Lab?
What will be the position of machine in GT cell if Form/To ratio of this machine using
Hollier II method is the lowest?
What will be the position of machine in GT cellif Form/To ratio of this machine using
Hollier II method is the highest?
1. Comments:
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