Work Cell Integration: Working with Existing Facilities

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Work Cell Integration Working with Existing
Facilities

• Working Conditions and Practices
• constraints/barriers for true
• work cell integration

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Cellular 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.

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Integration Revisited

• Integrate to make or become whole or complete
  (Websters, 1984)
• Integrate to form, coordinate, or blend into a
  functioning or unified whole unite (Websters
  Ninth, 1989, p. 628)
• Integration requires organization, visual
  control, cleanliness, safety, and sustained
  efforts to maintain positive working conditions
  and control over production output

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Work Cell IntegrationConstraints/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

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Companies Collect and Store

• Processes not in use
• Tools not in use
• Material not in use
• Chemicals not in use
• Parts/products not in use
• Equipment not in use
• Scrap / Material-Related Waste

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Processes Not In Use

• Consume Floor Space become obstructing
• Collect dust / filth
• Require moving and removing
• Can require significant maintenance to become
  operational
• Can require significant learning/retraining time
  to become operational

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Unused Equipment Sitting Idle
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Unused Equipment Floor Space Consumed
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Unused EquipmentCollecting Dust
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Unused Equipment Cluttering
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Materials Not In Use Scrap Disposal
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Materials Not In Use Raw Stock Storage
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Cells / Lines Often Lack Organization

• Tools become lost in drawers, bins, cabinets (do
  not have a place) lack of visual control
• Chemicals are often stored in unsafe manners
  containers often lack labeling
• Drawers and cabinets are magnets for clutter,
  personal equipment, unused tools, unused
  parts/material, etc.
• Ability to add value in work area becomes
  severely degraded

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Lack of Organization No labels
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Lack of Organization No Place
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Lack of Organization Clutter
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Lack of Organization Good luck in finding
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Lack of Organization No Place
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Lack of Organization No Place
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Lack of Organization Extra Junk
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Lack of Organization No Place
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Lack of Organization Extra Junk
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Lack of Organization No Labels
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Lack of Organization No Home
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Lack of Organization No Place
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Lack of Organization Extra Junk
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Lack of Organization No Labels
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Lack of Organization Process Clutter
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Work Areas Conditions May Be Unsanitary

• 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 slippery
• Electrical Hazards may exist
• Food or drink may be allowed in the work areas
  becoming a health hazard

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Work Area Conditions

• Processes, 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

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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Unclean Work Areas Failure to Maintain
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Integration Barriers

• Without 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.

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HazardsTrip
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HazardsTrip
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Hazards Food with Chemicals
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Hazards Food with Chemicals
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HazardsPoor Labeling
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HazardsPoor Labeling
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HazardsPoor Storage
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HazardsFlammable Materials Near Heat Source
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HazardsAccess to Safety Equipment
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HazardsStupid is hard to correct
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HazardsGravity
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HazardsGravity
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HazardsGravity
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HazardsElectrical Shock
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HazardsElectrical Shock
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HazardsElectrical Shock
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HazardsElectrical Shock
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HazardsElectrical Shock
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Company Culture Can Be Obvious
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Questions to Consider

• What 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?

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Questions to Consider

• What 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?

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Topics To Investigate Choose 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?).

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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).

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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 manufacturings challenges.

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Later

• You can be sure we will look into best
  manufacturing practices