Cellular Manufacturing

Boost Manpower Productivity & Process Efficiency with Lean Cellular Manufacturing

With increasing demand to deliver high-quality products faster and at lower costs,many manufacturers are turning to lean production strategies, among which cellular manufacturing stands out as a highly effective approach.

Cellular Manufacturing is the application of one-piece flow principles within a cell-based layout. This system transforms traditional batch-and-queue operations into flow production, drastically reducing lead time, inventory, and non-value-adding activities.

Lean cell is a set of collocated, physically linked machines performing a common sequence of process steps for a family of items and run by a team of multi-skilled operators with their work load balance to TAKT time.

Cellular manufacturing focuses on “synchronizing people, machines, and processes to flow at takt time,” which means aligning production pace with customer demand.

Benefits of implementing Cellular Manufacturing

30% to 40% fewer operators

80% to 90% less work in process

50% to 90% reduction in production of defectives

25% to 30% reduction in floor space requirements

Our Cellular Manufacturing Experience

0 + 40

Industries

0 + 150

Clients

0 + 2000

Projects completed

Steps of implementing Cellular Manufacturing

Current state assessment & planning

Classify products into families with similar routing or processing requirements.
Calculate TAKT time based on customer requirement
Conduct cycle time study / time & motion study & Identify time spent in Non value adding activities such as transportation, movement, waiting, rejects & breakdowns
Create current state of line balancing & set improvement targets

Cell design

Calculate target manpower based on total work content and TAKT time
Prepare improved line balancing chart based on workload balanced to TAKT as per target manpower
Create cutout based cell layout based on actual dimension and create cell based on one piece flow and various guidelines for establishing cells.

Implementation of Cell

Prepare for movement of machines and workstations
Implement the cell on gemba through physical movement of machines and workstations
Implement 5S & Visual management in cell
Establish hourly tracking boards on cell, capture and address all issues hindering the flow

Operators Training & Standard Work

Train operators on multi skilling and standard work
Develop Standard work documents such as Standard work combination sheet, standard operations chart and man machine chart
Continue problem solving and improvements in the cell until Improvement targets are achieved

Our Cellular Manufacturing Impact

0 % -50

Reduction in lead time

+ 0 % +40

Improvement in productivity

0 % -80

Reduction in WIP

0 % -50

Reduction in defects

Tools used for implementing Cellular Manufacturing

Product routing analysis

TAKT time

Time & Motion study

Line Balancing

One piece flow

Standard work

Our Clients Results

Home & Ofiice Furniture

Office Furniture Manufacturer boosts Productivity and reduce lead time through Lean Kaizen

Implementation of focussed lean kaizen workshops centered on redesigning layout and flow, stabilising methods, improving material supply, and strengthening daily controls have transformed the lines into high productivity flow-based cells.

Pharmaceuticals

Pharma manufacturers strengthen investment case and future capacity through Operational Due Diligence

An operational due diligence across two African pharma manufacturers benchmarked true capacity vs future demand, validated capex plans, and identified strong potential for OEE, manpower and GMP improvements before investment decisions.

Retail

Restaurant chain redesigns central bakery & prep kitchen layout to cut material movement, declutter flows and create a scalable backbone for growth

Using Lean Layout Design and Kaizen principles, RIBCON helped design a new macro-layout for the central facility that sharply reduces material movement, separates clean and dirty streams, and provides a scalable platform for future volume growth.

Advanced Lean Manufacturing Tools

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