The Lean tool cellular flow manufacturing involves the arrangement of equipment and workstations in a sequence. Additionally, this sequence supports a smooth flow of material and parts through the cell flow process. There are typically 8 types of cellular flow designs. Most importantly, they ensure minimal transport and delay.
Traditional Set-up Vs. Cellular Flow
Let’s take a look at different scenarios about a traditional set-up versus cellular flow. First off, here’s an example of a traditional set-up. 5 people manage 5 process steps, with a takt time of 60 seconds. You can see that there are different steps in different places! Consequently, there is a lack of balance and flow to takt time. Most importantly, note how excess transport, motion, and inventory are unavoidable in this set-up. Therefore, traditional set-ups eventually lead to poor process efficiency.
Figure 1: A traditional set-up
On the other hand, a cellular flow enables 3 people to manage 5 steps with a takt time of 60 seconds! Take a look:
Figure 2: A cellular flow
In a cellular flow, communication is fast and immediate. Additionally, transport is minimized. Figure 2 shows a ‘U’-shaped cell.
Cellular Flow Manufacturing in Different Sectors
Many think cellular flow manufacturing works well only with manufacturing companies. However, this is a myth! I have successfully tried cellular manufacturing ideas in the banking sector as well, and it works well. Moreover, it isn’t just banking that it works well with! Cellular flow manufacturing has a significant impact everywhere – even in IT!
Let us understand how cellular flow manufacturing works to the advantage of the service industry. Figure 3 (below) shows a traditional set-up from a BPO. It is a transactional process. Watch the information flow between the steps! Transactions are in a queue in the current set-up. This is a result of several communication loops
Figure 3 – A traditional set-up in services
By applying cellular flow ideas to this process, people sit close to one another. Consequently, unnecessary (over processed) communication loops disappear! Therefore, people can clarify their doubts with one another. Additionally, if there is only one transaction at a time (single piece flow), turnaround time will reduce and quality will improve.
Figure 4 – Cellular flow in services
If you understand the basic principles, you can customize them to any scenario! You can improve as you go by testing your ideas in pilot studies, carrying out Kaizens, identifying and removing barriers to flow. Furthermore, preconditions and techniques like 5S, load levelling, line balancing, flow and takt time, standard work, and Kanban will act as a good foundation for cellular flow in your workplace.
4 Stages of Cellular Flow
Figure 5 (below) explains the 4 stages to carry out cellular flow in your workplace. Firstly, assess the current state. Secondly, identify and remove non-value-added time and effort. Implementing cellular flow should be the last stage.
Figure 5 4 – Stages to implement cellular flow