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IMPLEMENTATION OF GROUP TECHNOLOGY IN LOCAL
MANUFACTURING INDUSTRY
Christopher Risandy Anak Rimes
Bachelor of Engineering with Honours
(Mechanical and Manufacturing Engineering)
2009
Faculty of Engineering
UNIVERSITY MALAYSIA SARAWAK
BORANG PENGESAHAN STATUS TESIS
Judul: IMPLEMENTATION OF GROUP TECHNOLOGY IN LOCAL
MANUFACTURING INDUSTRY
SESI PENGAJIAN: 2008/2009
Saya, CHRISTOPHER RISANDY ANAK RIMES
(HURUF BESAR)
mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik,
Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hakmilik Universiti Malaysia Sarawak.
2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat
salinan untuk tujuan pengajian sahaja.
3. Membuat pendigitan untuk membanguankan Pangkalan Data Kandungan Tempatan.
4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat
salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi.
5. ** Sila tandakan (√) di kotak yang berkenaan.
SULIT (Mengandungi maklumat yand berdarjah keselamatan atau kepentingan Malaysia
seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).
TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di
mana penyelidikan dijalankan).
TIDAK TERHAD
Disahkan oleh
_________________________ ___________________________ (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)
Alamat tetap: 36, Taman How Ching, ABG MOHD NIZAM ABG KAMARUDDIN
Jalan Stephen Yong, Nama Penyelia
Batu Kawa, 93250 Kuching,
Sarawak.
Tarikh: __________ Tarikh: __________
CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda
** Jika tesis ini SULIT dan TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi
berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai
SULIT dan TERHAD.
The Final Year Project Report as follow:
Title: Implementation of Group Technology in Local Manufacturing
Industry
Author: Christopher Risandy Anak Rimes
Matric: 13903
is hereby read and approved by:
_________________________________ __________________
Mr Abg Mohd Nizam Abg Kamaruddin Date
Project Supervisor
IMPLEMENTATION OF GROUP TECHNOLOGY IN LOCAL
MANUFACTURING INDUSTRY
CHRISTOPHER RISANDY ANAK RIMES
A dissertation submitted to
Faculty of Engineering, University Malaysia Sarawak
in partial fulfillment of the requirement for the
Degree of Bachelor of Engineering
With Honours (Mechanical and Manufacturing Engineering)
2009
Group Technology Dedication
ii
Dedicated to my parents, Mr. Mark Rimes and Mdm Rita Sian, family, and
friends
Group Technology Acknowledgements
iii
ACKNOWLEDGEMENTS
First and foremost I would like to thank my project supervisors, Mr Rasli Muslimen
and Mr Abang Mohd Nizam Abang Kamaruddin for guiding me throughout the project
with their wisdom, knowledge, experience and support.
Besides that I would also like to thank all the local companies for their cooperation
in this project. Special thanks to Mr. Augustine Sittin, the production manager of C. S.
Choice Food Industries for his time and contribution.
Next I would like to thank my family and friends who has given me the support and
encouragement.
Finally, thanks to everyone who were involved throughout the completion of this
project.
Group Technology Abstrak
iv
ABSTRAK
Projek ini adalah mengenai penyelidikan tentang pelaksanaan Teknologi Kumpulan
dalam industri pembuatan tempatan. Teknologi Kumpulan (GT) adalah satu falsafah
yang mengambil kira persamaan di antara masalah-masalah dan menerusi penggabungan
masalah-masalah tersebut, satu jalan penyelesaian dapat diperoleh yang seterusnya akan
menjimatkan masa dan tenaga. Konsep GT menekankan kepada pengurangan dimensi
sesuatu situasi yang ingin dikawal. Kilang akan dibahagikan kepada sel-sel yang lebih
kecil serba lengkap dengan mesin dan peralatan yang diperlukan untuk penghasilan
sesuatu kumpulan bahagian. Demi mencapai objectif projek, survei pos telah dihantar
kepada 48 syarikat dan hanya 8 yang membalas survei tersebut. Satu syarikat telah
dipilih sebagai kajian untuk penyelidikan ini. Syarikat tersebut terletak di kawasan
perindustrian Demak Laut dan terlibat dalam industri pemprosesan makanan. Temu
ramah telah dijalankan semasa lawatan ke kilang tersebut untuk mengenalpasti
kebarangkalian untuk melaksanakan GT dalam erti kata proses pembuatan dan susun
atur kilang di kilang tersebut. Susun atur baru kilang tersebut telah direka berdasarkan
maklumat semasa lawatan dan temu ramah dibuat. Objektif penyelidikan dan kertas
cadangan ini telah dicapai. Saranan untuk kajian selanjutnya adalah untuk meluaskan
skop kajian akibat daripada kekurangan syarikat yang sesuai di Kuching. Pengumpulan
maklumat juga harus dilakukan dengan menelefon syarikat untuk mempercepatkan
proses membalas survei. Adalah disarankan juga hanya syarikat tempatan patut dipilih
untuk kajian.
Group Technology Abstract
v
ABSTRACT
The project is about the study on the implementation of Group Technology in the
local manufacturing industry. Group Technology (GT) is a manufacturing philosophy
that states if 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. GT concept
emphasizes in reducing the dimension of the situation to be controlled. Instead of being
functionally laid out, the factory is divided into smaller cells in such a way that each cell
is equipped with all the machines and equipment needed to complete a particular family
of components. In achieving the project objectives, mail survey was sent to 48 samples.
Out of the 48 companies only 8 replied. Only one company was chosen as the case study
for this research. The company involves in food processing and is located in Demak
Laut Industrial Park. Observation and interview was done during the visit to the
company to identify the possibility of implementing and integrating GT concept in terms
of manufacturing processes and plant layout. A new plant layout was designed to be
proposed to the company based on the observation done during the factory visit and
interview. Objectives of the research and the proposal are achieved. Recommendations
for the research are to expand the scope of the project to a wider area due to the
insufficient sampling group which is suitable in Kuching. Information gathering should
include follow-up calls being made to the sampling groups to speed up the reply process.
It is also advised to choose local companies as the sampling group.
Group Technology Table of Contents
vi
TABLE OF CONTENTS
Content Page
Dedication ii
Acknowledgements iii
Abstrak iv
Abstract v
Table of contents vi
List of Tables x
List of Figures xi
List of Abbreviations xiii
CHAPTER 1: INTRODUCTION
1.0 Introduction 1
1.1 Project Objectives 2
1.2 Scopes of Project 2
1.3 Chapter Overview 4
CHAPTER 2: LITERATURE REVIEW
2.0 Introduction 5
2.1 History of Group Technology 5
Group Technology Table of Contents
vii
2.2 Fundamentals of Group Technology 7
2.3 Part Families 10
2.4 Part Classification and Coding 15
2.5 Production Flow Analysis 22
2.6 Application of Group Technology 25
2.7 Analysis in Group Technology 27
2.8 Case Studies 28
2.8.1 Group Technology cell design: 28
A case study
2.8.2 Application of Group Technology 29
Concept in Scheduling Customised
Bag Production
2.8.3 Production Flow Analysis Case 30
Study of Computational System
for Group Technology
CHAPTER 3: METHODOLOGY
3.0 Overview 31
3.1 Defining Objectives of Survey 33
and Sampling Group
3.2 Information Gathering 37
3.3 Analysis of Survey Data 38
3.4 Expected Problem during Project 40
Group Technology Table of Contents
viii
CHAPTER 4: RESULTS, ANALYSIS AND DISCUSSION
4.0 Overview 41
4.1 Survey Respond and Analysis 41
4.2 Questionnaire Analysis 43
4.3 Discussion 49
4.4 Case Study 51
4.4.1 Company Background 52
4.4.2 Observation of Space for Group 54
Technology Implementation
CHAPTER 5: PROPOSAL
5.0 Overview 60
5.1 Problem Statement and Assessment 60
5.2 Proposal Objectives 61
5.3 Methodology 63
5.3.1 Identification of Part Families 63
5.3.2 Designed New Layout 64
CHAPTER 6: CONCLUSION AND RECOMMENDATIONS
6.0 Conclusion 68
6.1 Recommendations 70
REFERENCES 71
Group Technology Table of Contents
ix
APPENDIX A Case Study: 74
Group Technology Cell Design: A case Study
APPENDIX B Case Study: 75
Application of Group Technology Concept in
Scheduling Customised Bag Production
APPENDIX C Questionnaire Sample (1) 76
APPENDIX D Questionnaire Sample (2) 77
APPENDIX E Designed Questionnaire 78
APPENDIX F Returned Questionnaire (A) 79
APPENDIX G Returned Questionnaire (B) 80
APPENDIX H Returned Questionnaire (C) 81
Group Technology List of Tables
x
LIST OF TABLES
Table
Page
Table 3.1: Lists of Sampling Group 33
Table 4.1: Respond of Survey on Returned Questionnaire 42
Table 4.2: Scaling of Annual Production Rate
45
Table 4.3: Scaling of Types of Products Being Produced
46
Table 4.4: Scaling of Number of Types of Machines in the Factory 47
Table 4.5: Scaling of Expected Benefits of Implementing Group Technology 48
Group Technology List of Figures
xi
LIST OF FIGURES
Figure Page
Figure 2.1: Parts With Similar Geometrical Properties 7
Figure 2.2: Cubical Parts that can be made on the Same Multi-axis
Machining Center
8
Figure 2.3: Part Families 10
Figure 2.4: Layout of Process Type Plant 11
Figure 2.5: Layout of Group Technology 12
Figure 2.6: Plant Layout Before Implementation of GT 13
Figure 2.7: Plant Layout After Implementation of GT 14
Figure 2.8: Structure for Opitz Classification and Coding 19
Figure 2.9: Rotational Parts that Can be Classified in Form Code (digits 1-5) 20
Figure 2.10: Code Number for MultiClass Coding System 22
Figure 2.11: Part-Machine Incidence Matrix or PFA Chart 24
Figure 2.12: Arranged PFA Chart Indicating Possible Machine Grouping 24
Figure 3.1: Project Flow Chart of Group Technology Implementation 32
Figure 4.1: Bar Chart of Awareness on Group Technology 44
Figure 4.2: Bar chart showing the Comparison of Numbers of the Companies
that are interested in Implementing Group Technology
44
Figure 4.3: Comparison between Company A, B and C Respectively 49
Group Technology List of Figures
xii
Figure 4.4: Frankfurter Process Flow Diagram 54
Figure 4.5: Burger Patty and Minced Meat Process Flow Diagram 55
Figure 4.6: Current Plant Layout of C. S. Choice Food Industries 57
Figure 5.1: Proposed New Plant Layout for C. S. Choice Food Industries 65
Group Technology List of Abbreviations
xiii
LIST OF ABBREVIATIONS
GT - Group Technology
USSR - Union of Soviet Socialist Republics
USA - United States of America
OIR - Organization for Industrial Research
PFA - Production Flow Analysis
SCIB - Sarawak Concrete Industries Berhad
Group Technology Introduction
1
CHAPTER 1
INTRODUCTION
1.0 Introduction
Group Technology (GT) is a manufacturing philosophy that states if 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. The objectives of GT are best
achieved in business concerned with small to medium batch production which represents
a major part of manufacturing industry. The traditional approach to this type of
manufacture is to make use of a functional layout in the factory where similar machines
are grouped according to type [1].
As a result of this form of machine layout, where only machining operations of a
particular type may be performed in a limited area of the workshop, the workpiece itself
must travel a considerable distance around the workshop before all the operations are
performed upon it. This usually leads to a long throughput time, thus, the planning of
process route becomes an extremely difficult task since a number of similar machine
tools may be considered at each point in the sequence of manufacturing operations.
Group Technology Introduction
2
As a result, a different concept of manufacturing organization and layout has been
developed to overcome the difficulties. The GT concept emphasise in reducing the
dimension of the situation to be controlled. Instead of being functionally laid out, the
factory is divided into smaller cells in such a way that each cell is equipped with all the
machines and equipment needed to complete a particular family of components. It has
been found that by switching to this type of cellular manufacture, many benefits of
flowline production can be attained in a batch production system [1].
1.1 Project Objectives
There are two main objectives for this project and they are as follows.
i. To study the potential of group technology in local manufacturing industry.
ii. To propose a system consists of group technology to the chosen company.
1.2 Scopes of the project
Malaysia has established a diverse and quickly-growing manufacturing sector that
plays an increasing role in the Malaysian economy. Malaysia built up its manufacturing
sector mainly in the 1970s and 1980s, utilizing its long-established industrial centers on
the island of Penang and the Klang Valley, its well-developed transportation
infrastructure (including seaports and railways), and the entrepreneurial skills of its
Group Technology Introduction
3
small and medium-sized businesses. The industrial sector initially consisted of oil
refining, machinery assembly, and light industries (including foodstuff processing and
textile manufacturing) [2].
Malaysian manufacturing sector was boosted by the extensive growth of the electric
assembly and electronics sectors. Malaysia became an important producer of radios,
television sets, stereo equipment, and other related products. There was further growth in
the manufacturing sector, especially in export-oriented electronics production, including
semiconductors, silicon wafers, and other items. Malaysia has become the world's third-
largest producer, and one of the world's largest exporters, of semiconductors [2].
The manufacturing division includes establishments engaged in the mechanical or
chemical transformation of materials or substances into new products. These
establishments are usually described as plants, factories, or mills and characteristically
use power driven machines and materials handling equipment. Establishments engaged
in assembling component parts of manufactured products are also considered
manufacturing if the new product is neither a structure nor other fixed improvement [2].
This project will cover the extent of implementation of GT in the local
manufacturing industry particularly in Kuching, Sarawak. Before that, in-depth research
and study on the topic would be done to gain knowledge, understanding the principles
and fundamentals of GT. The information collected would be used later to come up with
proposal of implementation to the selected company.
Group Technology Introduction
4
1.3 Chapter Overview
In the first chapter, an introduction to the topic was done. This section explained
briefly on what the project is all about. The objectives of the project were also defined as
well as the scope of the project. There is also an overview of every chapters included.
The second chapter is literature review. This chapter will cover the history of GT
and its development. Besides that, it would also include other components of GT such as
the fundamentals of GT, part families, application of GT and analysis in GT.
The third chapter is methodology. This chapter will describe on the strategy used to
do this research and to give the reader an overall understanding of all steps involved in
carrying out this project. It will cover objectives of survey and sampling group,
information gathering, analysis of survey data and expected problem during project.
The fourth chapter is where the results, analysis and discussion will be presented.
Data obtained from the questionnaires and interview will be analyzed and one company
will be chosen to be the case study for this research.
In the fifth chapter, proposal of GT implementation will be discussed. This
proposal will include the analysis and suggestions of the recommended new layout.
Chapter six would be the conclusion, including with the limitations and
recommendations of the research.
Group Technology Literature Review
5
CHAPTER 2
LITERATURE REVIEW
2.0 Introduction
In general, group technology (GT) is considered as a manufacturing philosophy
which identifies and exploits the similarity of parts and operation processes in the design
and the manufacture of products. GT is vital in the foundation for successful
development and implementation of computer-integrated manufacturing through the
application of the part family and its analysis.
2.1 History of Group Technology
The initial idea on GT first surfaced in 1925 where R. Flanders from the United
States presented a paper on organizing manufacturing at Jones and Lamson Machine
Company. In 1937, A. P. Sokolovski from the USSR suggested that parts of similar
configurations and features where all factors being equal should be manufactured in the
same way by a standardized technological and manufacturing process. S.P. Mitrofanov,
also from the USSR then expanded this theory and introduced GT. Mitrofanov stated
Group Technology Literature Review
6
that design simplification and standardization are the necessity to an effective GT
program. In 1937, a U.S.A. manufacturer announced a technique in their manufacturing
system, which was the same year Sokolovski published his paper. In 1949, a Swede
named A. Korling presented on “group production” which is an adaptation of production
line techniques to batch manufacturing. In his presentation he described that work was
divided in groups where each contained machine and tooling of certain purposes [3,4].
In 1963, GT was applied at Hopkinsons Ltd., in Huddersfield, England which was
similar to the one implemented at Forges et Ateliers several years earlier. GT was also
implemented at a machine tool manufacturing plant in Sringfield, Vermont in 1963.
Mitrofanov’s work was published in Russia and German in 1966. First International
Conference on Classification and Coding was held in Fort Lauderdale, Florida, United
States also in the year 1966. In 1967, the Second Conference on Classification, Coding
and Group Technology was held at Waldorf-Astoria Hotel in New York. In 1968, the
Third International Conference on Classification, Coding and Group Technology was
held in Fort Lauderdale, Florida [3,4].
In 1969, there was a conference organized by the International Labor Organization
at Turin, Italy, where the main topic being discussed at the conference was on the
meaning of GT. Also during the same year, Langston Division of Harris-Intertype of
New Jersey, United States applied GT where they transform a traditionally arranged
machine shop into “family of part” lines. The implementation has improved the
productivity by 50% and at the same time has reduced leadtimes to days rather than
weeks [3,4].
Group Technology Literature Review
7
2.2 Fundamentals of Group Technology
Grouping objects (i.e., components, parts, or systems) into families based on the
object features has been done using GT approaches. Similar components can be grouped
into design families, and modifying an existing component design from the same family
would lead to new designs. The philosophy of group technology is an important concept
in the design of advanced integrated manufacturing systems. GT classifies and codes
parts by assigning them to different part families based on their similarities in shape
and/or processing sequence [4].
Figure 2.1 below shows an example of three different components having similar
geometrical properties. All three parts are manufactured by using the same machine. The
main difference between each component is the machining process. All three
components are made from the same raw material which is a cylinder shaped rod.
Figure 2.1: Parts With Similar Geometrical Properties [10].
Group Technology Literature Review
8
Group technology is an example of optimizing the strategic perspective on machine
technology so that when the tactical aspects of the technology are considered, the results
could be for the better of the company. The similarities between processes, products and
materials can be used as the basis of grouping and as the basis of subsequent cellular
manufacturing [5]. Group technology can and has been successfully applied in
manufacturing, in production planning and control, in purchasing and in sales as well as
in process design, parts decisions and elsewhere in organizations [5].
Figure 2.2 below shows another example of different but similar in characteristics
components. All three cubicle parts looked different but are manufactured of the same
equipment which is the multi-axis machining center. The machine could orient the
component in various axis to execute different types of operation depending on the
instructions being input into it.
Figure 2.2: Cubical Parts that are made on the Same Multi-axis Machining Center [10].
