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choose the cellular approach while some opt for a monolithic cell structure instead of each cell acting as a logistics center.
“A large storage center can connect 10 or 15 individual machines, with transport of material from multiple processes covered under one system,” he says. “This means no need for fork- lifts and the associated time and money costs of transport.”
There is no right or wrong with var- ious layouts, it just depends on fabri- cators’ needs. Of course, cost is a factor, as well as space. Where some fabrica- tors may be able to accommodate a cell layout within a new building, oth- ers must deal with space and process constraints in existing structures.
Specific Cells for Specific Needs
“We ask fabricators what they are looking for when they consider automation,” says Reuther. “Do they want a small-cell approach, or a flexible
logistics center that can be fed with orders where they manage just one inventory compared to three?”
Some fabricators may manufacture three main product lines, with each of them providing enough work for one or two dedicated laser-cutting machines. In this case, according to Reuther, it makes sense to operate them as inde- pendent cells.
“Clearly distinctive production lines can benefit from this approach,” he says, “but it is not very flexible. With an A-B- C production line, what if production drops suddenly on A but increases on C? A fabricator can’t shift to the other cell without giving up efficiency and flow, and must change the inventory and ensure location of the right material in the right cell. A large storage system with six connected machines enables a fabricator to shift and prioritize work easily. Dedicated product lines benefit from smaller cells, but if jobs change frequently over time, multiple machines connected to a central storage center
enable the needed flexibility.”
Such smaller cells, as cellular manu-
facturing may have been described a decade or more ago, were, back then and in many cases today, essentially production islands. Bridging those islands these days are advanced com- munication software and manufacturing execution systems (MESs) that allow cells to work in concert, bringing flexi- bility where previously it did not exist.
“Even multiple individual cells served by a couple of storage towers can con- nect to an MES,” Reuther says, “bringing a greater level of freedom and flexibility, thus making cellular manufacturing more powerful than ever.”
Optimized Layouts
Serve Individual Sectors Well
Today, cellular-manufacturing lay- outs often reflect the industries served by fabricators.
“For example, agricultural manufac- turers tend to produce distinct products that change little from year to year, using
Fabrication: Cellular Manufacturing
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