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.

Group Technology is the realization

that many problems are similar, and
that by grouping similar problems, a
single solution can be found to a set of
problems thus saving time and effort.

Why Group Technology?

Average lot size decreasing

Part variety increasing
Increased variety of materials With diverse properties
Requirements for closer tolerances

Everyday Examples
1. Fast food chains
2. Doctors

A FAMILY OF PARTS

 Lack Of Common Database For

Mfg., Design...
Dont redesign the wheel
Automated process planning
Database to drive the automated factory

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
Contd

Other Benefits Of Group Technology

Easier to justify automation
Standardization in design
Data retrieval
Easier, more standardized process plans
Increases in quality

Gt affects
every operating and staff function.
It is more than merely a technique, but a total
Manufacturing philosophy.
DATA
PROCESSING

DESIGN
ENGINEERING

MAINTENANCE

INVENTORY

TOOL
ENGINEERING

PLANNING

ESTIMATING

PURCHASING

INDUSTRIAL
RELATIONS

ASSEMBLY

QUALITY
CONTROL

MANAGEMENT
MFG.
ENGINEERING

R&D
COST
ACCOUNTING

SALES

GT

SHIPPING &
RECEIVING

Three Techniques To Form Part Families

1. Tacit judgment or visual Inspection
May use photos or part prints
Utilizes subjective judgment
2. Production Flow Analysis
Uses information contained on the route sheet
(therefore only mfg. Info)
Parts grouped by required processing

Contd

3. Classification And Coding

Codes geometry/design and mfg.
Info about a component
Codes are alphanumeric strings
Easier to use for other analyses

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

Examples:
Part Design Attributes

Part Mfg. Attributes

Basic external shape

Basic internal shape
Material

Major processes
Minor operations
Fixtures needed

Length/diameter ratio
Surface finish
Tolerances-----machine tool Operation sequence
Major dimension Tooling
Batch size

GT Code--a Sequence Of Numerical Digits

Three major structures:
1. Monocode (or hierarchical structure)
A code in which each digit amplifies the
information given in the previous digit
Difficult to construct
Provides a deep analysis
Usually for permanent information
contd

2. Polycode (Or Chain-type Structure)

Each digit is independent of all others,
presents information not dependent
On previous ones
Easier to accommodate
Change
3. Mixed Code
Has some digits forming monocodes, but
strings them together in the general
Arrangement of a polycode

Reduction Of Mfg. Costs By Various

Steps Of Group Technology Applications
(Adapted From Ham442)

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

Hierarchical Structure
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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

Example:

Thirteen parts with similar manufacturing

Process requirements but different
Design attributes

Functional Layouts Are Inefficient

L
L

Drilling

Milling

Lathe

L
L

M
M

M
M

Grinding

L
L

M
Assembly

Receiving and
Shipping

PROCESS-TYPE LAYOUT

Group Technology Layout

L

G
A

Receiving

Shipping

Cellular Layout
Department #2
D

Department #1
M

D
I
L

Department #3
L

M
M

HIGH
PR

VOLUME

TRANSFER
LINE
SPECIAL
SYSTEM

FL
E
OD
UC

TIO

X IB

IL I
TY

NC
AP
AC
I

TY

FLEXIBLE
MANUFACTURING
SYSTEM
MANUFACTURING
Cells
STD. AND GEN.
MACHINERY

LOW

VARIETY

HIGH