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Cellular/Flow Manufacturing is the linking of manual and machine operations into the most efficient combination of resources to maximize value-added content while minimizing waste. The most efficient combination implies the concept of process balancing. When processes are balanced, the product flows continuously, parts movement is minimized, wait time between operations is reduced, inventory is reduced and productivity increases.
Workshop Objectives
This hands-on Workshop demonstrates how to link and balance manufacturing operations to reduce lead times, minimize work in process, optimize floor space usage, and improve productivity. Participants are lead through a 5-step process for designing and implementing work cells, using a live simulation. This process applies to both assembly and machining applications. This group training exercise is designed to precede a Cellular/Flow implementation, or Kaizen event.
• Understand the characteristics and benefits of cellular manufacturing
• Group manufactured products into product families
• Establish Takt Time for a product family
• Conduct a review of a work sequence
• Combine work to balance a production process
• Design an effective cell layout
Topics Covered
| • Defining Lean | • Work Balancing / Combination |
| • The Eight Wastes | • Cell Design and Construction |
| • Five Step Cell Design Process | • Cellular Manufacturing Case Studies |
| • The Product / Process Matrix | • Plant Layout Consideration |
| • Takt Time | • Keys to Success |
| • Tools for Cell Design and Kaizen | • Performance Impact and Benefits |
Kaizen Implementation Event
IMEC will facilitate a group of your employees through the Cellular/Flow process, implementing the techniques learned in the workshop. The team will redesign a process in such a way that it will result in substantial improvements in most, if not all process performance measures. When circumstances allow, the new process will actually be implemented and the results verified. When not possible, the team will have developed: a layout of the proposed process; projected performance measures for the new process; an implementation plan and an actions item list. Approximately 50% of all events result in actual physical changes by the end of the Kaizen Blitz. Normally, everything cannot be implemented during the two or three day Kaizen event. Therefore, the team will develop an action plan with assigned responsibilities and expected completion dates to insure that the necessary follow-up takes place.
Benefits of Cellular / Flow Manufacturing
An efficient flow-through manufacturing system will eliminate waste, minimize work in process, optimize floor space, reduce lead-time, and improve customer response time, leading to reduced costs and greater production capacity. |
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Continuous Process Improvement Links
Product/Process Flow Services |