Page 26 - MetalForming-Sep-2018-issue
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Fabrication: Cellular Manufacturing
similar parts from similar materials in similar thicknesses,” Reuther explains. “These manufacturers know that these products will be manufactured for the next 10 to 15 years, so they focus on larger systems due to volume and the expectation of constant work.
“Appliance fabricators, on the other hand, deal with a much higher variety of parts,” he continues. “They place importance on quickly producing
many part types. They tend to opt for several small cells that allow flexibility based on demand. Software connects these cells to help optimize produc- tivity. And, with most material being thin-gauge stainless steel, it doesn’t matter if it is stored in three or four towers, or just one. Due to lack of mate- rial variety, inventory poses only a minor challenge.”
These examples illustrate how cel-
lular layouts arise from various fabri- cator needs. Where agricultural sup- pliers may deal with known part types and volumes over an extended period but require a variety of materials in various thicknesses, appliance suppli- ers could face part variety but little material differentiation. Cell solutions exist for both. Some combination of these application attributes reveal other cellular possibilities, where the large system tackles high-volume, var- ied-material jobs while small cells run smaller-lot jobs.
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Transparency Keys Cell Advancements
“Transparency is the key to produc- tion efficiency, especially in cellular environments,” explains Reuther. “Knowing how a machine performed on the last shift, knowing the idle times and errors...how do you find out?”
Smart factories, using the advanced communication capabilities in newer equipment, combined with software that tracks, analyzes and helps manage all aspects of operations, bring cellular manufacturing to a whole new level via transparency of processes, machine utilization and workflow. Machines or software can notify operators or man- agement of issues, leading to almost instant response and resolution.
“That transparency dramatically reduces downtime and increases effi- ciency,” Reuther says. “Connectivity of machines that enable communication with a general software system is an absolute necessity for ideal shop-floor productivity. Otherwise, machines and processes would require constant mon- itoring by humans. Machines can ask for help or keep the system updated on job progress, ensuring that the next job will be ready to go.”
And, should troubles arise that can’t be solved inhouse, new technology such as remote monitoring by machine man- ufacturers, or augmental-reality glasses that let machine-builder technicians see what the fabricator sees, quicken troubleshooting and repair by leaps and bounds. The options cost less than fly- ing a technician out to take a look. MF
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MetalForming/September 2018
www.metalformingmagazine.com
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