Cell

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  Cellular layouts are the optimal flow based layout.  A cell is a close arrangement or setup of people, machines or workstations. The purpose of a cellular layout is to fulfill a processing sequence while simultaneously reducing wait times, transportation and other forms of muda.  In addition to removing various forms of waste, cells are very effective and promote and facilitate effective flow.  Cells can be in many different shapes and attempt to spread work evenly amongst the resources.  

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What should you do before building a cell?

• When moving from a functional layout to a cellular layout a best practice is that you should co-locate the equipment according to sequence before designing your cell.  In some cases, for example an office may not need to co-locate items because you mainly move computers, desks and other lighter items.  Whereas a shop floor that has monuments would need to be co-located before building your cell.​

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Different Cell Shapes
  A work cell is commonly thought of as a U-shaped or a C-shaped cell.  Truthfully speaking though, they can be designed in a variety of ways to fit your specific needs.  One important thing to remember is that the cells should not be designed in a mini functional layout.  They need to be organized by the flow of the process.  This will ensure that the cell is process based and not operational.  While there are many different shapes, cells are most commonly organized in:

1. Straight line or I shaped layouts.
2. L shaped layouts.
3. U shaped layouts.
4. C shaped layouts.
5. S shaped layouts.

Some things to keep in mind when designing your cells are:

• What size is your equipment?
• What is the shape of the equipment?
• Is the item in constant production?
• Is the material used on the cell difficult to move?

Cells should also be able to flow freely upstream and downstream and workers should be trained on the entire cell.  While cells may require a kaizen event to set up, they will also yield some massive advantages.  Some of those advantages include:

• Walking distances and transportation muda are reduced.
• Work in process is reduced.
• The communication of people increases.
• Line balancing of the cell and the entire value stream become much easier.
• Lead times are reduced.

Challenge:

• Do you work in a cellular layout?  What tips do you have for the community? Share your thoughts in the comments section below and receive a coupon to one of Lean Strategies International LLC's courses.

Learn more about cellular manufacturing online!