GROUP TECHNOLOGY

GROUP TECHNOLOGY
GT is a manufacturing philosophy in which
similar parts are identified and grouped
together to take advantage of their
similarities in manufacturing and design.
Similar parts are arranged into part
families.
eg. A factory manufacturing 10000 different
parts may be categorized into 50 families.

Each family will have some common

characteristics feature or parameters.

PART FAMILY
A part family is a collection of parts which
are similar either because of geometric
shape and size or because similar
processing steps are required in their
manufacture.
Three methods of identifying part family:
1.Visual inspection
2.Part classification and coding schemes
3.Production flow analysis (PFA Chart)

Grouping according to
geometric similarities

Grouping according to
manufacturing similarities

Plant Layout
&
Group
Technology
Process type
Layout

GT
(Cellular)
Layou

Advantages of GT
Standardization of part design and minimization of
design duplication
New parts can be developed using previous similar
designs.
Data reflecting the experience of the part designer and
manufacturing process planner are stored in a database.
Process plans are also standardized and scheduled more
Setup times are reduced and parts are produced more
efficiently.
Similar tools, clamps, jigs, fixtures and machinery are
shared.
Needs to be implemented CIM, CAD/CAM and cellular
manufacturing. Potential savings 5 to 75 %.

efficiently.

Classification and Coding of Parts

Design Attributes:

External and internal shapes and dimensions

Aspect ratio
Tolerances specified
Surface finish specified
Part function

Manufacturing Attributes:

Primary processes
Secondary and finishing processes
Tolerances and Surface finish
Sequence of operations
Tools, dies, fixtures and machinery
Production quantity and production rate

 Part Classification and Coding System

Classification means to sort similar parts
into predetermined groups based on
appropriate attributes (shape,manufacturing
process, material, etc.)
A code is a combination of letters and
numbers that are assigned to parts for
information processing

Coding Systems

Types of Coding:
Hierarchical coding (monocode)
Polycoding (chain type)
Decision-tree Coding (hybrid code)
Major Industrial Coding Systems:
Opitz System
Multiclass System
KK-3 system

Coding schemes
Hierarchical
1
1
1

2
2

31

3
2

 Chain
1
2
3
.
.

1
2
3
.
.

Decision Tree Classification

OPITZ SYSTEM
12345 6789 ABCD
- Basic code consist of first 9 digits. This
convey both design and manufacturing
data.
-First 5 digit 12345 called form code
- Next 4 digit 6789 called supplementary
code
- Next 4 digit ABCD called secondary code

A Simple Rotaional Part

MULTI CLASS SYSTEM

This developed by the organization for
industrial research.
This is relatively flexible.
This used for variety of diff types of mfg
product.
It uses a hierarchical or decision tree
coding structure.
Coding structure up to 30 digits.

MULTI CLASS SYSTEM

Digit
Function
0 code system prefix
1 main shape category
2,3 external and internal configuration
4 - machined secondary elements
5,6 Functional description
7-12 Dimensional data (length,diameter)
13-Tolerances
14,15 Material chemistry
16 Raw material shape
17- production quantity
18- machined element orientation

PRODUCTION FLOW ANALYSIS(PFA)

It does not use part classification and
coding system.
It does not use part drawing
It used to analyze the operation sequence
and machine routing.
PFA uses manufacturing data rather than
design data.
Dis adv: It provides no mechanism for
rationalizing the manufacturing routings.

PFA PROCEDURE

1.DATA COLLECTION
2. SORTING OF PROCESS ROUTINGS.
3.PFA CHART
4. ANALYSIS

 Part Family & Manufacturing Cell

Formation: General Procedure
1. Define the scope of the study including system boundaries
2. Identify the similarity attributes of interest
3. Simplify:
Group obviously similar parts into representative part-type
Group pieces of equipment that must stay together into
representative machine-type
4. Find process plans using part-types and machine types
found in the previous step
5. Determine the Part-Machine Incidence Matrix
based on the process plans found in the previous step
6. Find the best Product Families and Machine Cells using
clustering methods.

Manufacturing Cell Layout

Once machine clusters are identified, one
needs to decide the best machine layout to
implement.
For a good cell layout one must consider:
-Technological considerations
-Streamlined material flow
Hollier methods specifies the machine layout
that maximizes the proportion of in-sequence
moves within the cell.

Hollier Method
1. Develop the From-To Chart
2. Determine the From/To ratio for each
machine by dividing the From-sum by
theTo-sum for each machine
3. Arrange the machines in order of
decreasing From/To ratios
Machines with high ratios are placed at
the beginning of the flow.
In the case of ties, place machines with
higher From values first.

 Solve the problem using Hollier Method :

GT LAYOUT
1.Single machine cell
2.Group machine cell with manual
handling
3.Group machine cell with semi-integrated
handling
4.Flexible manufacturing system(FMS).

GT Layout