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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.
Average lot size decreasing Part variety increasing Increased variety of materials With diverse properties Requirements for closer tolerances
VOLUME
SPECIAL SYSTEM FLEXIBLE MANUFACTURING SYSTEM MANUFACTURING Cells STD. AND GEN. MACHINERY
LOW
HIGH
VARIETY
Everyday Examples 1. Fast food chains 2. Doctors, dentists and also manufacturing
A FAMILY OF PARTS
Production Family
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
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Other Benefits Of Group Technology Easier to justify automation Standardization in design Data retrieval Easier, more standardized process plans Increases in quality
Gt affects most every operating and staff function. It is more than merely a technique, but a total Manufacturing philosophy.
DATA PROCESSING MAINTENANCE TOOL ENGINEERING ESTIMATING INDUSTRIAL RELATIONS QUALITY CONTROL R&D COST ACCOUNTING DESIGN ENGINEERING SALES INVENTORY PLANNING PURCHASING ASSEMBLY MANAGEMENT MFG. ENGINEERING
GT
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
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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 Basic external shape Basic internal shape Material Length/diameter ratio Surface finish Tolerances-----machine tool Operation sequence Major dimension Tooling Batch size Part Mfg. Attributes Major processes Minor operations Fixtures needed
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
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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
CODE SPACE
Hierarchical Structure
32XX
321X Mechanical
323X Transmission
3231 322X
3233
3221
3223
322 2
Hybrid Structure
Polycode
Monocode
Polycode
12 18 24 36 Time (months)
Proliferation Of Parts
Selection of optical instrument parts in one company, Illustrating the similarity between certain components
Conceptual design
Design concept can be coded. Code is a rough model of the conceptual design.
Existing designs
Design modification
Retrieve designs of similar shape or function and use them as the examples.
New Design
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
L L L L
L L L L
M M M A A
M M M
Assembly
D D
Grinding
D D
G G G
G G G
A A
PROCESS-TYPE LAYOUT
Shipping
Cellular Layout
Department #2 D D M I Department #1 D I Department #3 L L D M I L M M
Form Code
2nd Digit main shape External shape element 3rd Digit rotational machining Internal shape element 5th Digit 4th Digit additional plane surface holes teeth & matching forming Machining of plane surfaces Machining of plane surfaces Other holes and teeth Other holes teeth and forming
0 1 2 3 4 5 6 Non-rotational 7 8 9
Main shape
Rotational
Main shape
Rotational machining
Special
Main shape
Main shape
Special
Engineering drawing Process planner XX X Process planning system Process Code or other form of input
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) Process planning bridges design and manufacturing
Bridge
Design
Manufacturing
Variant Process Planning Uses the similarity among components to retrieve existing process plans (which can be modified) Overview: Two Stages For VP Systems 1. Preparatory stage Existing parts coded & classified (i.E. Gt is a prerequisite) Part families organized Standard plans developed Databases created (Note: this stage is labor intensive)
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Coding
Family One
Family Formation
(Indexed by Family Matrix)
Process Plan
Coding
Family Search
Process Plan
Editing