Production System - Part 2 of 3

(TKI 3105):
1 Introduction and GT
Andi Sudiarso & Colleagues

Mechanical & Industrial Engineering

Faculty of Engineering
Gadjah Mada University

Materials Part 2

Introduction & Group Technology

Theory of Constraints

Computer Integrated Manufacturing

Automated Material Handling

Forecasting

References

Fogarty, D.W., Blackstone, J.H., Hoffmann, T.R., 1991,

Production and Inventory Management, South-Western
Publishing Co., Ohio
Elsayed, E.A., Boucher, T.O., 1994, Analysis and Control of
Production Systems, Prentice Hall Inc., New Jersey
Other related books and articles.

Markings

Quizzes and assignments (8%)

Midterm exam (25%)

Total (Part 2): 33%

e-Lisa (1)

Register at elisa1.ugm.ac.id

e-Lisa (2)

Register at Komunitas SisproTI-UG_ASA

Types of Layout
The tree main types of layout are
1. line layout (product oriented)
2. functional layout (process oriented)
3. group layout (family oriented)

Line Layout
Line layout is used in simple process industries, in
continuous assembly, and for mass production of
components required in very large quantities.

Functional Layout
In functional layout, all machines of the same type
are laid out together in the same section under the
same foreman. Each foreman and his team of
workers specialize in one process and work
independently. This type of layout is based on
process specialization.

Group Layout
In group layout, each foreman and his team
specialize in the production of one group of parts
and co-operate in the completion of common task.
This type of layout based on component
specialization.

Functional vs. Group

What is group technology?

Group technology (GT) is manufacturing philosophy
in which similar parts are identified and grouped
together to take advantage of their similarities in
design and manufacture (Elsayed and Boucher,
1994).
For example, parts requires external turning such as
shafts are grouped together, while parts require
grinding and drilling such as plates are grouped
separately. Machines are arranged such that each
machine is assigned to produce only one group of
parts.

A Group
A group is a list of machines, selected for layout
together in one place, because it contains all
necessary facilities to complete the processing of a
family of parts. A family of parts can only be defined
by relating it to a particular group of machines and a
group by relating it to a family.
The group technology organization of production
transforms a difficult job-shop production control
problem into a more simplified series of flow shop
problems through simplification of routings.

Family of Parts
Family of parts is a
collection of parts which are
similar either because of
geometric shape and size or
because similar processing
steps are required in their
manufacture.
Family of parts is the
process of grouping parts
into logical families so that
they can be produced by the
same group of machines,
tooling and people with only
minor changes on procedure
or setup.

Grouping parts into families

1. Visual inspection
by looking at the physical parts
2. Part Classification and Coding
by examining the individual design and/or
manufacturing attributes of each part
3. Production Flow Analysis
by using the information contained on route
sheets rather than part drawing

Group Schemes
Grouped parts (family of parts)

Ungrouped parts
Grooved

Slotted

Threaded

Drilled

Machined

Cell layout with two operators

Implementation of GT
1. Controlling the parts that will be manufactured
by reduction of new design, elimination of
redundant parts, etc.
2. Analyzing the flow of parts through the shop
floor
3. Coding parts and then grouping them into
families based on their manufacturing processes
4. Making machine group and changing the layout
to eliminate complex routes

Potential Obstacles
1. Management resistance to change
x unwilling to devote the time and energy
2. Extensive data requirements
x proper identification needs detailed item
descriptions
3. High start-up cost
x part characteristics are not available
without the aid of automated information
storage and retrieval systems which
usually incur high expenses until GT is in
place

The Benefits (1)

1. Reduced purchasing cost through volume
purchasing
x purchase fewer different items at higher
volumes
2. Faster lead time
x fewer parts, quickly identify the tooling
and materials needed

The Benefits (2)

3. Better accuracy of cost estimation
x estimate the future price range with a
standard cost database
4. Quicker reaction to design changes
x quickly identify newer material or parts
that conform to newer designs and
specifications
5. Better communication between the buyer
and the supplier
x eliminate the human errors with GT
classification

More Technical Benefits

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Improved product design

Reduced work-in-process inventory
Improved routing & machine loading
Reduced setup & production times
Simplified production planning &
control
Simplified maintenance

DETAILED BENEFITS OF GROUP TECHNOLOGY

It affects all areas of a company, including:

engineering
equipment specification
facilities planning
process planning
production control
quality control
tool design
purchasing
service

DETAILED BENEFITS OF GROUP TECHNOLOGY

1. Engineering design
Reduction in new parts design
Reduction in the number of drawings through
standardization
Reduction of drafting effort in new shop drawings
Reduction of number of similar parts, easy retrieval
of similar functional parts, and identification of
substitute parts

DETAILED BENEFITS OF GROUP TECHNOLOGY

2. Layout planning
Reduction in production floor space required
Reduced material-handling effort

DETAILED BENEFITS OF GROUP TECHNOLOGY

3. Specification of equipment, tools, jigs, and fixtures
Standardization of equipment
Implementation of cellular manufacturing systems
Significant reduction in up-front costs incurred in the
release of new parts for manufacture

DETAILED BENEFITS OF GROUP TECHNOLOGY

4. Process planning
Reduction in setup time and production time
Alternative routing leading to improved part routing
Reduction in number of machining operations and
numerical control (NC) programming time

DETAILED BENEFITS OF GROUP TECHNOLOGY

5. Production control
Reduced work-in-process inventory
Easy identification of bottlenecks
Improved material flow and reduced warehousing
costs
Faster response to schedule changes
Improved usage of jigs, fixtures, pallets, tools,
material handling, and manufacturing equipment

DETAILED BENEFITS OF GROUP TECHNOLOGY

6. Quality control
Reduction in number of defects leading to reduced
inspection effort
Reduced scrap generation
Better output quality
Increased accountability of operators and supervisors
responsible for quality production, making it easier to
implement total quality control concepts.

DETAILED BENEFITS OF GROUP TECHNOLOGY

7. Purchasing
Coding of purchased part leading to standardized
rules for purchasing
Economies in purchasing possible because of
accurate knowledge of raw material requirements
Reduced number of part and raw materials
Simplified vendor evaluation procedures leading to
just-in-time purchasing

GROUP TECHNOLOGY
Group technology is a management
strategy to help eliminate waste caused by
duplication of efforts.