work cell integration: working with existing facilities
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Work Cell Integration: Work Cell Integration: Working with Existing FacilitiesWorking with Existing Facilities
Working Conditions and Practices: constraints/barriers for true
work cell integration
Cellular ManufacturingCellular Manufacturing“A manufacturing cell is a small unit,
consisting of several workstations. A workstation usually contains either one machine or several machines with each machine performing a different operation on the part” (Kalpakjian & Schmid, 2006).
Cells are made up of people, machines, devices, and support systems.
Integration RevisitedIntegration RevisitedIntegrate = “to make or become whole or
complete” (Websters, 1984)Integrate = “to form, coordinate, or blend into
a functioning or unified whole : unite” (“Webster’s Ninth”, 1989, p. 628)
Integration requires organization, visual control, cleanliness, safety, and sustained efforts to maintain positive working conditions and control over production output
Work Cell Integration:Work Cell Integration:Constraints/BarriersConstraints/Barriers
People attitudes – complacency, apathy, laziness – unwillingness to cooperate (company culture)
Presence of hazardous working conditions – sanitation level, temperature levels, air quality levels
Organization of the work area (cell/line) – Design of working area
Space available for operations – How space is utilized
Companies Collect and StoreCompanies Collect and StoreProcesses not in useTools not in useMaterial not in useChemicals not in useParts/products not in useEquipment not in useScrap / Material-Related Waste
Processes Not In UseProcesses Not In UseConsume Floor Space – become obstructingCollect dust / filthRequire moving and removingCan require significant maintenance to
become operational $$$Can require significant learning/retraining
time to become operational $$$
Unused Equipment: Sitting IdleUnused Equipment: Sitting Idle
Unused Equipment: Floor Space ConsumedUnused Equipment: Floor Space Consumed
Unused Equipment:Collecting DustUnused Equipment:Collecting Dust
Unused Equipment: ClutteringUnused Equipment: Cluttering
Materials Not In Use: Scrap DisposalMaterials Not In Use: Scrap Disposal
Materials Not In Use: Raw Stock StorageMaterials Not In Use: Raw Stock Storage
Cells / Lines Often Lack OrganizationCells / Lines Often Lack OrganizationTools become lost in drawers, bins, cabinets
(do not have a place)= lack of visual controlChemicals are often stored in unsafe
manners – containers often lack labelingDrawers and cabinets are magnets for
clutter, personal equipment, unused tools, unused parts/material, etc.
Ability to add value in work area becomes severely degraded
Lack of Organization: No labelsLack of Organization: No labels
Lack of Organization: No PlaceLack of Organization: No Place
Lack of Organization: ClutterLack of Organization: Clutter
Lack of Organization: Good luck in findingLack of Organization: Good luck in finding
Lack of Organization: No PlaceLack of Organization: No Place
Lack of Organization: No PlaceLack of Organization: No Place
Lack of Organization: Extra JunkLack of Organization: Extra Junk
Lack of Organization: No PlaceLack of Organization: No Place
Lack of Organization: Extra JunkLack of Organization: Extra Junk
Lack of Organization: No LabelsLack of Organization: No Labels
Lack of Organization: No HomeLack of Organization: No Home
Lack of Organization: No PlaceLack of Organization: No Place
Lack of Organization: Extra JunkLack of Organization: Extra Junk
Lack of Organization: No LabelsLack of Organization: No Labels
Lack of Organization: Process ClutterLack of Organization: Process Clutter
Work Areas Conditions May Be Work Areas Conditions May Be UnsanitaryUnsanitary
Machines/equipment may be filthy – gages, instructions may be difficulty or impossible to read – safety mechanisms may not be visible or accessible
Floor surfaces may be slipperyElectrical Hazards may existFood or drink may be allowed in the work
areas becoming a health hazard
Work Area ConditionsWork Area ConditionsProcesses, tools, material, chemicals,
parts/products, equipment, and scrap not in use can hinder production and production improvement efforts.
Personnel can become used to unsafe, unclean, and unorganized work areas – this can make them unproductive
Cells / lines may fail to integrate because of work area conditions
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Unclean Work Areas: Failure to MaintainUnclean Work Areas: Failure to Maintain
Integration BarriersIntegration BarriersWithout organization, visual control,
cleanliness, safety, and sustained efforts, cell operations fail to work together (to unite, to integrate) in an efficient manner
Companies can adopt sloppy practices that can affect performance, perception, and safety.
Companies must adopt a culture that minimizes non-value-added (wasteful) practices to increase control over production output.
Hazards:TripHazards:Trip
Hazards:TripHazards:Trip
Hazards: Food with ChemicalsHazards: Food with Chemicals
Hazards: Food with ChemicalsHazards: Food with Chemicals
Hazards:Poor LabelingHazards:Poor Labeling
Hazards:Poor LabelingHazards:Poor Labeling
Hazards:Poor StorageHazards:Poor Storage
Hazards:Flammable Materials Near Heat SourceHazards:Flammable Materials Near Heat Source
Hazards:Access to Safety EquipmentHazards:Access to Safety Equipment
Hazards:Stupid is hard to correctHazards:Stupid is hard to correct
Hazards:GravityHazards:Gravity
Hazards:GravityHazards:Gravity
Hazards:GravityHazards:Gravity
Hazards:Electrical ShockHazards:Electrical Shock
Hazards:Electrical ShockHazards:Electrical Shock
Hazards:Electrical ShockHazards:Electrical Shock
Hazards:Electrical ShockHazards:Electrical Shock
Hazards:Electrical ShockHazards:Electrical Shock
Company Culture Can Be ObviousCompany Culture Can Be Obvious
Questions to ConsiderQuestions to ConsiderWhat are production barriers not covered in this
session?
What is the first step to correcting wasteful practices (such as clutter, unsanitary conditions, safety)?
Do you understand how this waste affects production output? What consequences exist if these practices are not acknowledged and corrected?
Questions to ConsiderQuestions to ConsiderWhat should a work cell/area look like? What
should be the standard?
What can be done to combat obvious manufacturing wastes? As an engineer, engineering manager, or production leader, what do you do? How do you do this? What are your other options/choices?
Topics To Investigate: Topics To Investigate: Choose OneChoose One
Review five+ Sources on 5S. Determine important points (What is 5S? Why is 5S important? How is 5S conducted?).
Review five+ Sources on visual control in manufacturing (What is visual control? Why is visual control important? What are methods of visual control?).
Review five+ sources on worker satisfaction in manufacturing (What makes laborers satisfied in their jobs? Why is labor satisfaction important? How can companies improve production labor satisfaction?).
Do The Following:Do The Following: 1. Select quality sources – synthesize them to be sure
you have true focus on the topic. You should find common themes.
2. Create a training handout for each student in class based on your sources. Include images, charts, graphics, quotes. Focus on topic.
3. Credit your sources (last name, year) or (“title”, year) in your handout. Do provide a complete citation in a references section.
4. Provide copies of your sources to the assessor (“the prof”).
Next Time:Next Time:You will share your topic handout
We will explore the 8 Deadly Wastes and how they affect integration, efficiency, safety, and production flow. This session will reveal other constraints/barriers and will hopefully further sensitize you to manufacturing’s challenges.
LaterLater
You can be sure we will look into “best” manufacturing practices
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