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Lean Office – Layout & CellsLean Office – Layout & Cells

http://http://www.managementsupport.comwww.managementsupport.com

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Cellular Layout - Work CellsCellular Layout - Work Cells

Special case of product-oriented layout - in what is Special case of product-oriented layout - in what is ordinarily a process-oriented facilityordinarily a process-oriented facility

Consists of Consists of differentdifferent operations brought together to operations brought together to make a productmake a product

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Requirements for Cellular ProductionRequirements for Cellular Production

Identification of families of processes - group technology Identification of families of processes - group technology codescodes

High level of training and flexibility on the part of the High level of training and flexibility on the part of the employeesemployees

Either staff support or flexible, imaginative employees to Either staff support or flexible, imaginative employees to establish the work cells initiallyestablish the work cells initially

Mistake proofing at each station in the cellMistake proofing at each station in the cell

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Work Cells, Focused Work Centers and Work Cells, Focused Work Centers and the Focused Factorythe Focused Factory

Work Cell A temporary assembly-line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility

Focused WorkCenter

A permanent assembly-line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility

Focused Factory A permanent facility to produce a product or component in a product-oriented facility

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Cellular WorkplacesCellular Workplaces

FG RM

Includes Every StepIncludes Every Step

Source InspectionSource Inspection

Point of Use StoragePoint of Use Storage

Flexible OutputFlexible Output

Reduced Lot SizeReduced Lot Size

Simplified HandlingSimplified Handling

Visual Goals & MetricsVisual Goals & Metrics

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Line BalancingLine Balancing

Determine cycle time by taking the demand (or production Determine cycle time by taking the demand (or production rate) per day and dividing it into the productive time available rate) per day and dividing it into the productive time available per dayper day

Calculate the theoretical minimum number of work stations by Calculate the theoretical minimum number of work stations by dividing total task time by cycle timedividing total task time by cycle time

Perform the line balance and assign specific assembly tasks to Perform the line balance and assign specific assembly tasks to each work stationeach work station

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Line Balancing StepsLine Balancing Steps

1.1. Determine tasks (operations)Determine tasks (operations)2.2. Determine sequenceDetermine sequence3.3. Draw precedence diagramDraw precedence diagram4.4. Estimate task timesEstimate task times5.5. Calculate cycle time Calculate cycle time 6.6. Calculate number of work stationsCalculate number of work stations7.7. Assign tasks Assign tasks 8.8. Calculate efficiencyCalculate efficiency