The objective of this research is to analyze if there is a business case to create cells in Company X.
The conclusion is based on some assumptions about the location. We assumed that the first cell is located in the sheet metal center and the second cell is located in the painting department.
First of all, it can be concluded that it is possible to create cells in Company X. The similarity coefficient algorithm and the direct clustering technique result in the same three cells. By using the similarity coefficient algorithm we validated the results of the direct clustering technique. Since the two different clustering methods result in the same cells, we can say that the clustering that results from these two methods is a good clustering.
The proposed facility layout that results from the three cells does not differ too much from the current layout. The changes between the factory layout with the three cells and the current facility layout is summarized below:
1) Seven machines in the first cell are currently placed in the same location. Only the stainless steel welding machine is placed in the stainless steel welding department. 2) The welding machines and the grinding machine in the second cell are currently located next to each other in the welding department. The painting machine is set down in the painting department. The degreasing machine is located in the painting department. We quantitatively proved that the decrease in departmental flows is equal to 32.4% in case the three cells are created in Company X. This percentage is due to five routings. The table below, which is derived from table E.2 in the Appendix, presents the routings that actually cause the decrease in flows between departments. We can see that 57.3% of decrease in flows is due to the (sub)routings in the second cell. By creating the second cell the decrease in flows is equal to 1441 part moves that is equal to 57.3% of all moves. The other three (sub)routings belong to the first cell and cause 42.7% of the decrease of all departmental moves. (Sub)routing # of orders in 2015 # of flows before cell # of flows after cell per year before cell per year after cell W072,W091 779 1 0 779 0 W072,W091,W071 662 1 0 662 0 Sum 1441 0.573 W041,W061 544 1 0 544 0 W061,W073 309 1 0 309 0 W041,W038,W061 219 1 0 219 0 Sum 1072 0.427 7.2 Recommendation This thesis gives a recommendation about implementing cells based on the routings. The use of manufacturing cells can be recommended to the production department of Company X. Based on what is found with the clustering analyzes, we can say that Company X should create the first and the second cell. The table in the previous section proves that the decrease in departmental flows is due to the creation of the first cell containing cutting, bending and stainless steel welding machines and the second cell containing the steel welding machines, the grinding machine and the paint shop. We quantitatively proved that placing the stainless steel welding machine next to the machines in the sheet metal center contributes to 42.7% of the total decrease (32.4%) in departmental moves. The moving of the steel welding machines in the painting department contributes to the 57.3% of the total decrease (32.4%). The decrease in distance between machines after implementing cells in the given locations is equal to 42.6% and the decrease in travel time is equal to 38.4% (see Table …show more content…
That is why this analysis does a recommendation based on the routings. Based on the routings we can recommend to create cells within the factory. There are other factors that might influence the suitability of manufacturing cells. It is possible that is not beneficiary for Company X to create cells because of some other factors like space requirements. For sure there are other layouts that can be investigated as well. The hybrid of the functional layout and the cellular layout can be suitable for the company. Therefore it is good to develop layout alternatives. Some nice to know research areas that might affect the decision to create cells are the following: space requirements, layout alternatives and the cost and investment in the