Page 217 - How To Implement Lean Manufacturing

CHAPTER 13

Cellular Manufacturing

ellular manufacturing is a key element of Lean manufacturing—this is common
knowledge. What is not so commonly understood is how powerful a variation
Creduction tool cells can be by virtue of their design. This is a well-kept secret. In
addition to explaining the benefits of cells, and how they fit into the battle of waste
reduction, I will guide you through an actual redesign of a complex production line that
was converted from a long flow line into cellular manufacturing. Grab a pencil and
pocket calculator and follow me through the calculations as we redesign the line and
improve the production rate by 63 percent, with virtually no capital expenditures—and less
manpower!
You will be amazed!

Cellular Manufacturing

The Definition of a Cell
A cell is a combination of people, equipment, and workstations organized in the order
of process flow, to manufacture all or part of a production unit. I make little distinction
between a cell and what is sometimes called a flow line. However, the implication of a
cell is that it:
• Has one-piece, or very small lot, flow
• Is often used for a family of products
• Has equipment that is right-sized and very specific for this cell
• Is usually arranged in a C or U shape so the incoming raw materials and
outgoing finished goods are easily monitored
• Has cross-trained people for flexibility

Cells are advertised as taking up less space than “island” production, but I find this
is not always the case.

The Advantages of Cells
Cells are an integral part of Lean manufacturing. The use of cells is so basic that in the
TPS (Toyota Production System) it is not even questioned. For Toyota, that works.
Unfortunately, for others, cells may not work in quite the same way, so it is worth
understanding the benefits and drawbacks of cells before we embark on a full-blown
effort to convert everything to cells.

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