What is Cellular/Flow Manufacturing?
When processes are balanced, the product flows continuously and customer demands are easily met. Cellular/Flow Manufacturing is the linking of manual and machine operations into the most efficient combination of resources to maximize value-added content while minimizing waste. The most efficient combination implies the concept of process balancing. Only in a balanced process will the product continually flow. As a result, parts movement is minimized, wait time between operations is reduced, inventory is reduced, and productivity increases.
Benefits
- Maximize value added by each worker
- Minimize part movement and inventory
- Reduce lead times, cycle times, and waiting times
- Increase productivity and quality performance
- Free up floor space
- Improve efficiency of cross-training workers
- Increase communication
- Increase flexibility
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Successes
Through the implementation of a U-shaped system design, a precision machine shop increased production flow by 50% , increased capacity by 15%, developed a new product line, and maintained the workforce at full capacity.
Manufacturing cells were created in a small metal machining firm that resulted in a 65% reduction in WIP, improved production quality, and reduced material transport time from 45 minutes to just 5 minutes.
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A cut and sew operation implemented a work cell that lead to increased product vol ume, a reduction in finished goods inventory shelving from 800 to 32 linear feet, and a 32% increase in profits. |
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