While a single-process workflow groups different types of equipment in the same production area to facilitate faster production, the "batch and queue" method places similar types of equipment in the same production area, where material and inventory are queued up for batch production.
The batch and queue method can be prone to production and transportation delays. However, a single-process workflow transfers the product from one piece of equipment to another, moving it from one state of completion to the next and thus avoiding delays in the production line.
The number of preferred workcells depends upon the product. Consequently, a company in the manufacturing industry that has a diversified portfolio may need many workcells to achieve a single-process flow. Workcells are faster and more efficient than the batch and queue production system, provided there is enough product volume within the manufacturing process.
Cellular manufacturing ensures that every workcell is capable of completing the product "just in time" (JIT) for the next cell to take over. In the batch and queue method, a batch can get stuck somewhere in the manufacturing process. Alternatively, the manufacturing process can get slowed down due to non-moving inventory on account of manufacturing delays. The JIT system used in cellular manufacturing avoids these pitfalls since skilled personnel identify defects and prevent defective components or products from moving forward.
Yet another practice that cellular manufacturing makes use of is the "pull" system. This concept requires a workcell to pull in what is required from the preceding cell. This system ensures the manufacture of only those components that the product requires. Production does not exceed the number of products the customer requires.
Workcells are optimized for speed. Each cell handles an optimum volume of material. This is extremely advantageous because it saves time and cost as well as reduces inventory.
It's commonly believed that cells should be square or rectangular, but they really don't have a particular shape. A cell can be straight, U-shaped, circular, or any other shape depending on how it will be used.
The purpose of implementing cellular manufacturing is to reduce waste and provide maximum resource efficiency. Manufacturing the entire product along a single product line by minimizing processes and eliminating overproduction is the essential aim of cellular manufacturing.
