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Cellular manufacturing is an application of the group technology concepts for factory
reconfiguration and shop floor layout design. A part family can be parts similar
in size or parts created using similar manufacturing steps. Typically, a cell is
dedicated to a single part family.
Cellular manufacturing does have some important human resource issues to consider:
- Operators must be trained properly to perform tasks including inspection and simple
maintenance
- Cross functional training is critical since operators perform a variety of tasks
and move between workstations and cells as the need arises
- Operators should be trained on Team Building
- Supervisors become Coaches. Cell teams require only guidance. Supervisors facilitate,
assist and guide the overall effort.
- Compensation issues: Cell employees usually receive the higher pay because they
are better qualified to do multiple tasks. We recommend implementation of an incentive
program that provides incentives on the basis of results and incremental improvements.
- Management may be concerned that there will be resistance from employees when the
result is actually opposite. Typically, any initial resistance disappears once employees
understand the win-win situation at hand.
- Cells need support from several functions including product engineering, material
management, manufacturing engineering, QC/QA, maintenance and management. It is
vital to implementation success that this support is committed, visible and consistent.
Team Selection
Most crucial to the implementation of cellular manufacturing is team selection.
To help determine who is best to include in your team, identify the skills required
for each step by creating a Process Map. Clarify the roles and responsibilities
of the roles you need filled.
Once the skills are identified, determine the potential team members. Explain to
potential members what the nature of the task is and get a feel for their interest.
What will you look for in your team members? Understanding the importance of selecting
the right team cannot be overemphasized. Both objective and technical criteria should
be established, including skills in:
- teamwork
- interpersonal skills
- leadership skills
- change adaptation
- positive thinking
Develop a checklist for selecting these members based on the needs of the cell.
This can also be used in setting goals for those who wish to grow in their own skill
sets.
From here you will need to do some negotiating. You will need to meet with affected
Supervisors to discuss:
- Overall priority
- Current structure and plans
- Current authorities and relative power of team leaders
- Potential team members and the support they will need
Negotiate to acquire members best suited for the team. Renegotiate as necessary
with the help of management and a detailed implementation plan.
Skill Matrices
Match skills to tasks. Create a matrix to define who is best qualified to perform
specific tasks. This will be the document used for contracting your team to the
project: aiding in obtaining commitment as well as communicating responsibilities
and expectations. Determine what training is needed and implement a training plan.
Make sure communication lines are established, open and well used. The success of
the program is contingent on the team dynamic and the goals set. Communication is
key—learn to listen and help others to do the same. What are the communication channels
and links? Who provides and who expects what? Can the team members accomplish the
tasks assigned?
Team Management
Develop trust and provide the team a reason to be motivated. Learn to manage team
morale and create a system to encourage teamwork. Make your team an example of how
successful teams cause great things to happen. Start with a pilot cell—be sure the
product family chosen has the most potential for success. Stockpile if possible
to provide an alternate source during implementation. When changes are necessary,
communicate the reason for these changes in order to gain acceptance and understanding
from your team. Be confident in implementation.
Designing the Cell
Cell design should be based on your project needs. Keep in mind the following when
designing the cell:
- product life cycle
- continuous, flowing work through the cell
- proper allocation of resources for gauging and tooling
- aggressive update of equipment and processes
- cell development is evolutionary and always in a state of flux
- challenges in facility changes due to structure and age
Involve your team and their knowledge in the construction of the cell. Understanding
throughput is essential to cell development—do not underestimate the contribution
and acceptance of the team once the concept is understood. Ultimately, the logistics
and cell construction is only a small part of the battle. Creating a culture where
a team can flourish is the hard part. This task requires a true leader. Can you
meet the challenge? -JPP
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