Comparison of lean cellular manufacturing organization models: Multiple case study analysis

Abstract

Cellular manufacturing represents a production system arrangement in which machines, tools, workers, and devices are grouped to produce a single product or a group of products with similar production requirements. By implementing cellular manufacturing, it is possible to significantly influence the elimination of the seven types of process Lean losses: transport, inventory, unnecessary motion, waiting, overproduction, overprocessing, and defects. There are various models of a cellular manufacturing organization, and some of the most widely used and studied include Toyota Sewing System, Bucket Brigades, Working Balance, and Rabbit Chase. This paper aims to present different types of lean cellular manufacturing organizations. By reviewing the literature, the advantages and disadvantages of individual types of cellular manufacturing will be systematized. In the practical part of the paper, the theoretical assumptions will be confirmed, and the impact and robustness of individual types of cellular manufacturing will be explored in different situations. Simulations were performed in real conditions on real products to demonstrate the efficiency of individual types of cellular manufacturing organizations depending on the duration of technological operations. The goal was also to examine the robustness of individual types of cellular organization in case of the absence of certain operators or insufficiently trained operators. The criteria used to compare different cellular models were productivity, non-conformance, WIP inventory, time to deliver the first correct piece, and flow time. Simulations were performed for the Toyota Sewing System, Bucket Brigade, Working Balance, and Rabbit Chase cellular manufacturing concepts. The simulation results indicate significant differences in the performance of individual concepts, where the difference in some criteria can reach up to 100%.