GROUP TECHNOLOGY

Group Technology:
Group technology is a manufacturing philosophy to increase production
efficiency by grouping a verity of parts having similarities of shape, dimension,
and/ or process route.

Thus in GT similar parts are identified and grouped together to take

advantage of their similarities in design and production.

This grouping philosophy results in increased manufacturing efficiencies.

Efficiencies are due to reduced step times, lower in process inventories, better
scheduling, streamlined material flow. Improved quality. Improved tool control,
and the use of standardized process plans.
 PART FAMILIES:
A Part family 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.

Grouping according to Grouping according to

geometric similarities manufacturing similarities
METHODS FOR PART FAMILY FORMATION:
•Visual inspection
•Parts classification and coding system
•Production flow analysis

1. Visual inspection method: It is the simplest and least expensive

method. It involves looking at parts, photos of parts, or drawings of parts and
arranging them into similar groups.
2. Parts classification and coding method: Coding is a systematic process of
establishing an alphanumeric value for parts based on selected part features.
Classification is the grouping of parts based on code values.

In parts classification and coding, the various design and/or manufacturing attributes
of a part are identified, listed and assigned a code number.

The part classification system fall into one of the following three categories
1. Design attributes
2. Manufacturing attributes
3. Both design and manufacturing attributes

Part design attributes part manufacturing attributes

Basic external shape Major production process
Basic internal shape Minor operations
Rotational or rectangular shape Operation sequence
Major dimensions Major dimension
Minor dimensions Production time
Material type Tools required
Part function Fixtures required
Surface finish Batch size
The coding structure is have three basic code structures used in group technology
application
1. Hierarchical codes ( or monocodes or tree structure)
2. Attribute codes (or polycodes or chain type structure)
3. Decision tree codes ( or hybrid codes or mixed codes)

1. Hierarchical codes ( or monocodes or tree structure): In hierarchical structure

the interpretation of each successive symbol depends on the value of the
preceding symbols. Each symbol amplifies the information contained in the
preceding digit, so a digit in the code cannot be interpreted alone.

2. Attribute code: In this structure the interpretation of each symbol in the

sequence does not depend on the value of preceding symbols. That is each
digit in this code represents information in its own right and does not directly
qualify the information provided by the other digits.

3. Decision tree (or ) Hybrid code: A hybrid code captures the best features of
the hierarchical and polycode structures. This system is also known as
decision tree coding and it combines both design and manufacturing
attributes.
CODING SYSTEMS:

1. Opitz classification system

2. MICLASS system
3. DCLASS system
4. KK-3 system
5. CODE system
6. CUTPLAN system
7. RNC system
8. Part analog system
9. Brisch system
10. COFORM

Mostly in industries they are using first five systems.

1. Opitz classification system:
The opitz system was developed by H.Opitz of the university of Aachen
in Germany. In fact, it was the most popular and one of the first published
classification and coding schemes for mechanical parts.

This system uses alpha – numeric symbols to represent the various attributes
of a part.

The Opitz coding scheme uses the following digit sequence:

12345 6789 ABCD
The first five digit (12345) code the major design attributes of a part and are
called the “form code”.

The next four digit (6789) are for coding manufacturing related attributes and
are called the “ supplementary code”

The letters (ABCD) code the production operation and sequence and are
referred to as the “secondary code”. The secondary code can be designated by
the firm to serve its own particular needs.
BASIC STRUCTURE OF OPITZ CODE SYSTEM:
 EXAMPLE :

Step 1: The total length of the part is 1.500 overall diameter 0.75 L/D = 2 Digit1 = 1
Step 2: External shape: Steeped on both ends with screw thread on one end Digir2 = 5
Step 3: Internal shape: Part contains a through hole Digit 3 = 1
Step 4: Plane surface machining: None Digit 4 = 0
Step 5: Auxiliary hole, Gear teeth, etc: None Digit 5 = 0

The form code in opitz system is 15100

2. MICLASS system: MICLASS stands for Metal institute classification system. This
system was developed by Netherlands organisation for applied scientific research.

MICLASS system is also referred as Multiclass system.

The MICLASS classification number can range from 12 to 30 digits. The first 12
digits are universal codes that can be applied to any part. The next 18 digit are
called supplementary digits.

the first 12 digits are mandatory and are used to classify the engineering and
manufacturing characteristics of a part.
Digits Attributes
1 st digit Main shape
2nd and 3rd digits Shape elements
4 Position of shape elements
5&6 Main dimensions
7 Dimension ratio
8 Auxiliary dimension
9 &10 Tolerance codes
11 & 12 Material codes
 3. DCLASS coding system: DCLASS stands for Design and classification
information system. The DCLASS part family code is comprised of eight digit
partitioned into five code segments.

•First segment (consisting three digits) is used to denote the basic shape.

•Second segment ( fourth digit) is used to specify the complexity of the part (
holes, slots, special surface finish).

•Third segment ( fifth digit) is used to specify the overall size of the coded
part.

•Fourth segment (sixth digit) is represents precision.

•Final segment (two digit) is used to denote the material type.

B 1 1 2 3 4 A 1
Basic shape
Form features
Size
Precision
Material
Production flow analysis (PFA): Production flow analysis (PFA)
developed by Burbridge in 1971, is a method for identifying part families and
associated machine groupings that uses the information contained on
production route sheets rather on part drawings.

In PFA, work parts with identical or similar routings are classified in to

part families.

It may be noted that PFA neither uses a classified and coding system
nor part drawings to identify families. Instead, it uses the information such as
part number, operation sequence, lot size,etc., contained on the route sheet.
STEPS INVOLVED IN PFA:

1. Data collection
2. Sortation of process routings
3. Preparation of PFA chart
4. Cluster analysis

1. DATA COLLECTION:

The step in the PFA procedure is collect the necessary data.

The route sheets of all the components to be manufactured in the shop are
prepared. The route sheet should contain the part number and operation sequence.

Other data that can be collected/ obtained from route sheet/operation sheet
include lot size, time standards, and annual demand.
2. SORTATION OF PROCESS ROUTE: the second step in the PFA is to arrange the parts
into groups according to the similarity of their process routings.

A typical card format is required for organising the data such as the part
number, sequence of code, and lot size.

Then a Sortation procedure is used to arrange the parts into ‘packs’. A pack
is nothing but a group with identical process routings. Some pack may even contain
only one part number.

3. PFA chart: A PFA chart is a graphical representation of the process used for each
pack. It is a tabulation of the process or machine code numbers for all of the part
pack s.
The PFA chart also known as ‘Part-machine incidence matrix’ or
‘Component machine incidence matrix’.
 Parts
Machines P1 P2 P3 P4 P5 P6 P7 P8 P9
M1 1 1 1 1
M2 1 1
M3 1 1 1
M4 1 1 1
M5 1 1
M6 1 1
M7 1 1 1
4. Cluster analysis: From PFA chart related grouping are identical and rearranged into a
new pattern that brings together packs with similar machine sequence.

Parts
Machines P1 P8 P2 P4 P6 P7 P9 P3 P5
M1 1 1 1 1
M5 1 1
M4 1 1 1
M7 1 1 1
M3 1 1 1
M6 1 1
M2 1 1

PART FAMILIES: CELL GROUPS:

PF1 = (P1,P8) C1 = (M1,M5)
PF2 = (P2,P4,P6) C2 = (M4,M7)
PF3 = (P3,P5,P9) C3 = (M2,M3,M6)
EXAMPLE:
Consider a problem of 5 machines and 10 parts. Try to group
them by using Rank Order Clustering Algorithm.
Components
Machines 1 2 3 4 5 6 7 8 9 10
M1 1 1 1 1 1 1 1 1 1
M2 1 1 1 1 1
M3 1 1 1 1
M4 1 1 1 1 1 1
M5 1 1 1 1 1 1 1 1

Table 1
 Binary weight
29 28 27 26 25 24 23 22 21 20

Components
Machines 1 2 3 4 5 6 7 8 9 10 Decimal
equivalent

M1 1 1 1 1 1 1 1 1 1 1007
M2 1 1 1 1 1 451
M3 1 1 1 1 568
M4 1 1 1 1 1 1 455
M5 1 1 1 1 1 1 1 1 1020

Table 2
21
 Binary weight

29 28 27 26 25 24 23 22 21 20

Components

Binary Machines 1 2 3 4 5 6 7 8 9 10
weight
24 M5 1 1 1 1 1 1 1 1
23 M1 1 1 1 1 1 1 1 1 1
22 M3 1 1 1 1
21 M4 1 1 1 1 1 1
20 M2 1 1 1 1 1
Decimal
equivalent
28 27 27 27 28 20 28 26 11 11
Table 3 22
 Binary weight

29 28 27 26 25 24 23 22 21 20

Components
Binary Machines 1 5 7 2 3 4 8 6 9 10 Decimal
weight equivalent

24 M5 1 1 1 1 1 1 1 1 1020
23 M1 1 1 1 1 1 1 1 1 1 1019
22 M3 1 1 1 1 900
21 M4 1 1 1 1 1 1 123
20 M2 1 1 1 1 1 115
Decimal
equivalent
28 28 28 27 27 27 26 20 11 11

Table 4

23
 Production flow analysis
Part Routing Times Ave.
• N={101, 102, 103, 104, no (min) dimensi
on
105}
101 D1-M1-V1 9-12-14 100
• M={drill1, drill2, mill1, 102 D2-M2-V1 5-11-14 250
mill2, Vbore1, Vbore2} 103 D1-M1 7-9 700

• M={D1, D2, M1, M2, 104 M2-V2-D2 8-12-5 100

105 V1-M1-D1 7-10-12 200
V1, V2}
 Step1

Mij 101 102 103 104 105 2^i

D1 1 0 1 0 1 2
D2 0 1 0 1 0 4
M1 1 0 1 0 1 8
M2 0 1 0 1 0 16
V1 1 1 0 0 1 32
V2 0 0 0 1 0 64
Mij*2^i 42 52 10 84 42
 Step2
Mij 103 101 105 102 104 Mij*2^j
D1 1 1 1 0 0
D2 0 0 0 1 1
M1 1 1 1 0 0
M2 0 0 0 1 1
V1 0 1 1 1 0
V2 0 0 0 0 1
Mij*2^i 10 42 42 52 84
Mij 103 101 105 102 104 Mij*2^j
D1 1 1 1 0 0 14
D2 0 0 0 1 1 48
M1 1 1 1 0 0 14
M2 0 0 0 1 1 48
V1 0 1 1 1 0 28
V2 0 0 0 0 1 32
Mij*2^i 10 42 42 52 84
 Step3
Mij 103 101 105 102 104 Mij*2^j
D1 1 1 1 0 0 14
M1 1 1 1 0 0 14
V1 0 1 1 1 0 28
V2 0 0 0 0 1 32
D2 0 0 0 1 1 48
M2 0 0 0 1 1 48
 Manufacturing Cell Layout
• Once machine clusters are identified, one needs to
decide the best machine layout to
implement.
• For a good cell layout one must consider:
• -Technological considerations
• -Streamlined material flow
• Hollier methods specifies the machine layout that
maximizes the proportion of in-sequence
moves within the cell.
 Hollier Method
• 1. Develop the From-To Chart
• 2. Determine the From/To ratio for each
machine by dividing the ‘From-sum’ by the‘To-
sum’ for each machine
• 3. Arrange the machines in order of
decreasing From/To ratios
• • Machines with high ratios are placed at the
beginning of the flow.
• • In the case of ties, place machines with
higher ‘From’ values first.
Example:
 Flexible Manufacturing System
• A highly automated GT machine cell,
consisting of a group of processing stations
(usually CNC machine tools), interconnected
by an automated material handling and
storage system, and controlled by an
integrated computer system
 Five Types of FMS Layouts

• 1.In-line
• 2.Loop
• 3.Ladder
• 4.Open field
• 5.Robot-centered cell
 In-line FMS Layouts
The machines and handling system are arranged in a line. It
is most appropriate for a system in which the part progress from
one workstation to the next in a well defined sequence with no
back flow. The operation of this type of system is very similar to
transfer type. Work always flows in unidirectional path as shown in
Fig.
 Loop FMS Layouts
The basic loop configuration is as shown in Fig. The parts usually move in
one direction around the loop, with the capability to stop and be transferred to any
station. The loading and unloading station are typically located at one end of the
loop.
 Ladder FMS Layouts
The loading and unloading station is typically located at the same
end. The sequence to the operation/transfer of parts from one machine
tool to another is in the form of ladder steps as shown in Fig.
 Open field FMS Layouts
The configuration of the open field is as shown in fig. The loading and
unloading station is typically located at the same end. The parts will go through all
the substations, such as CNC machines, coordinate measuring machines and wash
station by the help of AGV’s from one substation to another.
 Robot-centered cell FMS Layouts
Robot centered cell is a relatively
new form of flexible system in which one
or more robots are used as the material
handling systems as shown in Fig.
Industrial robots can be equipped with
grippers that make them well suited for
handling of rotational parts.
 FMS Components
• Hardware components
– Workstations - CNC machines in a machining type
system
– Material handling system - means by which parts are
moved between stations
– Central control computer - to coordinate the activities
of the components so as to achieve a
– smooth overall operation of the system
• Software and control functions
• Human labor
 Computer Functions in a FMS

• NC part programming - development of NC

programs for new parts introduced into the
system
• Production control - product mix, machine
scheduling, and other planning functions
• NC program download - part program commands
must be downloaded to individual stations
• Machine control - individual workstations require
controls, usually CNC
 Computer Functions in a FMS
• Work part control - monitor status of each work part in
the system, status of pallet fixtures, orders on
loading/unloading pallet fixtures
• Tool management - tool inventory control, tool status
relative to expected tool life, tool changing and
resharpening, and transport to and from tool grinding
• Transport control - scheduling and control of work
handling system
• System management - compiles management reports on
performance (utilization, piece counts, production rates,
etc.)
Duties Performed by Human Labor
• Loading and unloading parts from the system
• Changing and setting cutting tools
• Maintenance and repair of equipment
• NC part programming
• Programming and operating the computer
system
• Overall management of the system
 FMS Applications
 Machining –most
common application of
FMS technology
 Assembly
 Inspection
 Sheet metal processing
(punching, shearing,
bending, and forming)
 Forging
 FMS Benefits
• Higher machine utilization than a
conventional machine shop due to better
work handling, off-line setups, and improved
scheduling
• Reduced work-in-process due to continuous
production rather than batch production
• Lower manufacturing lead times
• Greater flexibility in production scheduling