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Work Cell Integration: Working with Existing Facilities

Work Cell Integration: Working with Existing Facilities. Working Conditions and Practices: constraints/barriers for true work cell integration. Cellular Manufacturing.

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Work Cell Integration: Working with Existing Facilities

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  1. Work Cell Integration: Working with Existing Facilities Working Conditions and Practices: constraints/barriers for true work cell integration

  2. Cellular Manufacturing • “A manufacturing cell is a small unit, consisting of several workstations. A workstation usually contains either one machine or several machines with each machine performing a different operation on the part” (Kalpakjian & Schmid, 2006). • Cells are made up of people, machines, devices, and support systems.

  3. Integration Revisited • Integrate = “to make or become whole or complete” (Websters, 1984) • Integrate = “to form, coordinate, or blend into a functioning or unified whole : unite” (“Webster’s Ninth”, 1989, p. 628) • Integration requires organization, visual control, cleanliness, safety, and sustained efforts to maintain positive working conditions and control over production output

  4. Work Cell Integration:Constraints/Barriers • People attitudes – complacency, apathy, laziness – unwillingness to cooperate (company culture) • Presence of hazardous working conditions – sanitation level, temperature levels, air quality levels • Organization of the work area (cell/line) – Design of working area • Space available for operations – How space is utilized

  5. Companies Collect and Store • Processes not in use • Tools not in use • Material not in use • Chemicals not in use • Parts/products not in use • Equipment not in use • Scrap / Material-Related Waste

  6. Processes Not In Use • Consume Floor Space – become obstructing • Collect dust / filth • Require moving and removing • Can require significant maintenance to become operational $$$ • Can require significant learning/retraining time to become operational $$$

  7. Unused Equipment: Sitting Idle

  8. Unused Equipment: Floor Space Consumed

  9. Unused Equipment:Collecting Dust

  10. Unused Equipment: Cluttering

  11. Materials Not In Use: Scrap Disposal

  12. Materials Not In Use: Raw Stock Storage

  13. Cells / Lines Often Lack Organization • Tools become lost in drawers, bins, cabinets (do not have a place)= lack of visual control • Chemicals are often stored in unsafe manners – containers often lack labeling • Drawers and cabinets are magnets for clutter, personal equipment, unused tools, unused parts/material, etc. • Ability to add value in work area becomes severely degraded

  14. Lack of Organization: No labels

  15. Lack of Organization: No Place

  16. Lack of Organization: Clutter

  17. Lack of Organization: Good luck in finding

  18. Lack of Organization: No Place

  19. Lack of Organization: No Place

  20. Lack of Organization: Extra Junk

  21. Lack of Organization: No Place

  22. Lack of Organization: Extra Junk

  23. Lack of Organization: No Labels

  24. Lack of Organization: No Home

  25. Lack of Organization: No Place

  26. Lack of Organization: Extra Junk

  27. Lack of Organization: No Labels

  28. Lack of Organization: Process Clutter

  29. Work Areas Conditions May Be Unsanitary • Machines/equipment may be filthy – gages, instructions may be difficulty or impossible to read – safety mechanisms may not be visible or accessible • Floor surfaces may be slippery • Electrical Hazards may exist • Food or drink may be allowed in the work areas becoming a health hazard

  30. Work Area Conditions • Processes, tools, material, chemicals, parts/products, equipment, and scrap not in use can hinder production and production improvement efforts. • Personnel can become used to unsafe, unclean, and unorganized work areas – this can make them unproductive • Cells / lines may fail to integrate because of work area conditions

  31. Unclean Work Areas: Failure to Maintain

  32. Unclean Work Areas: Failure to Maintain

  33. Unclean Work Areas: Failure to Maintain

  34. Unclean Work Areas: Failure to Maintain

  35. Unclean Work Areas: Failure to Maintain

  36. Unclean Work Areas: Failure to Maintain

  37. Unclean Work Areas: Failure to Maintain

  38. Unclean Work Areas: Failure to Maintain

  39. Unclean Work Areas: Failure to Maintain

  40. Unclean Work Areas: Failure to Maintain

  41. Unclean Work Areas: Failure to Maintain

  42. Unclean Work Areas: Failure to Maintain

  43. Unclean Work Areas: Failure to Maintain

  44. Unclean Work Areas: Failure to Maintain

  45. Unclean Work Areas: Failure to Maintain

  46. Unclean Work Areas: Failure to Maintain

  47. Integration Barriers • Without organization, visual control, cleanliness, safety, and sustained efforts, cell operations fail to work together (to unite, to integrate) in an efficient manner • Companies can adopt sloppy practices that can affect performance, perception, and safety. • Companies must adopt a culture that minimizes non-value-added (wasteful) practices to increase control over production output.

  48. Hazards:Trip

  49. Hazards:Trip

  50. Hazards: Food with Chemicals

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