Group technology ppt @ bec doms

1. GROUP TECHNOLOGY

2. GROUP TECHNOLOGY GROUP TECHNOLOGY IS A MANUFACTURING TECHNIQUE AND PHILOSOPHY TO INCREASE PRODUCTION EFFICIENCY BY EXPLOITING THE “UNDERLYING SAMENESS” OF COMPONENT SHAPE, DIMENSIONS, PROCESS ROUTE, ETC.

5. FLEXIBILITY PRODUCTION CAPACITY TRANSFER LINE SPECIAL SYSTEM FLEXIBLE MANUFACTURING SYSTEM MANUFACTURING Cells STD. AND GEN. MACHINERY VOLUME HIGH VARIETY LOW HIGH

6. Everyday Examples 1. Fast food chains 2. Doctors, dentists and also manufacturing A FAMILY OF PARTS

7. Production Family

9. Benefits Of Group Technology Reductions in Throughput time Set-up time Overdue orders Production floor space Raw material stocks In-process inventory Capital expenditures Tooling costs Engineering time and costs New parts design New shop drawings Total number of drawings Cont’d

10. Other Benefits Of Group Technology Easier to justify automation Standardization in design Data retrieval Easier, more standardized process plans Increases in quality

11. Gt affects most every operating and staff function. It is more than merely a technique, but a total Manufacturing philosophy. GT DESIGN ENGINEERING DATA PROCESSING MAINTENANCE TOOL ENGINEERING ESTIMATING INDUSTRIAL RELATIONS QUALITY CONTROL R & D COST ACCOUNTING SALES INVENTORY PLANNING PURCHASING ASSEMBLY MANAGEMENT MFG. ENGINEERING SHIPPING & RECEIVING

14. Types Of Classification And Coding Systems GT coding can benefit many facets of the Firm and fall into one of 3 categories: 1. Systems based on part design Attributes 2. Systems based on part mfg. Attributes 3. Systems based on design and mfg. Attributes

15. Examples: Part Design Attributes Basic external shape Basic internal shape Material Part Mfg. Attributes Major processes Minor operations Fixtures needed Length/diameter ratio Surface finish Tolerances-----machine tool Operation sequence Major dimension Tooling Batch size

18. POPULATION SPACE CODE SPACE P C MAPPING FROM POPULATION SPACE TO CODE SPACE H

19. UNF thread Transmission Hierarchical Structure Hydraulic Electrical Mechanical 32XX 321X 322X No thread UNC thread 3222 323X Power Receiving 3232 3231 3233 3221 3223

20. Monocode Polycode Polycode Hybrid Structure

21. Reduction Of Mfg. Costs By Various Steps Of Group Technology Applications (Adapted From Ham 442 ) Not All Cost Savings Are Immediate... Improvements in Engineering Design Materials Management & Purchasing Benefits Production Control Benefits Manufacturing Engineering Benefits Tooling & Setup Benefits Management Benefits Overall Cost Reduction & Increased Productivity 0 6 12 18 24 36 Time (months)

23. Conceptual design Coding (rough model) Retrieval existing designs Existing designs Design modification New Design Design archive Retrieve designs of similar shape or function and use them as the examples. Design concept can be coded. Code is a rough model of the conceptual design.

24. Technique: 1. Determine part and machine requirements 2. Numerically code each part Geometry (& size) Material Other specifications (tolerance, Surface finish) 3. Form a family of similar parts which use (Largely) the same set of machine tools 4. Lay out of each cell (a group of machine Tools) to make a family of parts 5. Design group tooling

25. Example: Thirteen parts with similar manufacturing Process requirements but different Design attributes

26. Functional Layouts Are Inefficient PROCESS-TYPE LAYOUT Lathe Milling Drilling Grinding Assembly Receiving and Shipping L L L L L L L L M M M M M M A A A A D D D D G G G G G G

27. Group Technology Layout Shipping L M D L M D G A A Receiving L L M G G

28. Department #2 Department #3 Department #1 D D M I D M L L I D M L M I Cellular Layout

29. 1st Digit part class Positions with a digit 2nd Digit main shape 3rd Digit rotational machining 4th Digit plane surface matching 5th Digit additional holes teeth & forming Form Code Opitz coding and classification system. Special Non-rotational Special Rotational 9 8 7 6 5 4 3 2 1 0 Internal shape element Rotational machining Main bore & rotational machining Other holes and teeth Other holes teeth and forming Other holes teeth and forming Machining of plane surfaces Machining of plane surfaces Machining of plane surfaces External shape element Main shape Main shape Main shape Main shape Supplim- entary code Digit 6 7 8 9 Dimensions Material Original shape of raw materials Accuracy

31. Process Planning “ Process planning” is that function within a manufacturing Facility that establishes which machining processes and Parameters are to be used (as well as those machines capable Of performing these processes) to convert (machine) a piece Part from its initial form to a final form predetermined (usually by a design engineer) from an engineering drawing. (I.E. The preparation of the detailed work instructions to Produce a part) Bridge Design Manufacturing Process planning bridges design and manufacturing

33. Part Drawing Coding Family Formation Process Plan Family One Standard Plan File (Indexed by Family Matrix) 1. Preparatory Stage Of Variant Process Planning

34. 2. Production Stage Of Variant Process Planning Coding Family Search Standard Plan File Editing Standard Plan Retrieval Process Plan