Page 122 - DMGT501_OPERATIONS_MANAGEMENT

Operations Management

Notes
Example: Telco, Jamshedpur, has different machine shops and dye shops whose output
is finally fed into the assembly line.
When considering a new technique such as Cellular Layout, managers need to thoroughly look
at past practices as a guide to changing the manufacturing environment.

The U-shaped assembly line: At any airport, it is common to see baggage in the arrival area
being distributed using U-shaped conveyor belts. There is a trend to move from traditional
longitudinal assembly lines to U-shaped assembly lines, especially in Cellular Layouts. Not
only is it useful particularly when there is a single worker in the line taking care of all the work-
stations, but it also consumes less space. The U shape of the line cuts the walking distance of the
worker by almost half.
Assembly line balances frequently result in unequal work-station times. Flexible line layouts,
such as the U-shaped line with work sharing, could help resolve the imbalance and are a common
way of dealing with this problem. The closeness of the work-stations, is used by the Japanese, to
allow workers to help a fellow worker catch up, thus increasing teamwork among workers. U-
shaped assembly lines are being successfully used by Matsushita Electric Co. of Japan by using
a single worker in the line. In addition, the U-shaped line reduces material handling as the entry
and exit points of the material on the line are nearby. A trolley which brings the raw material for
the line may take back the finished goods in a single round.

Caselet Manufacturing: Toyota Style

oyota's 'lean production' system is a part of the generic system of 'Cellular
Manufacturing'. The 'Toyota Production System' called 'lean production' by some,
Thas been heralded by many commentators as the future for competitive
manufacturing. It is a team concept and incorporates a philosophy of constantly reducing
production costs through the progressive elimination of waste. This waste is seen
everywhere in the manufacturing operation, and includes excessive work or 'over-
production'. This has given rise to the just-in time system (JIT).
JIT is a simple principle that includes 'produce and deliver finished goods just-in-time to
be sold, sub-assemblies just-in-time to be assembled into finished goods, and purchased
materials just-in-time to be transformed into finished parts'.

Advantages and Disadvantages

Some of the advantages of Cellular Layouts are that overall performance often increases by
lowering costs and improving on-time delivery. Quality should increase as well, though that
might take other interventions beyond the layout change. Other advantages are given below:
1. Lower work-in-process inventories,

2. A reduction in materials handling costs,
3. Shorter flow times in production,
4. Simplified scheduling of materials and labour,

5. Quicker set-ups and fewer tooling changes, and
6. Improved functional and visual control.

116 LOVELY PROFESSIONAL UNIVERSITY