Cell Design and Pull Systems 160

This class covers the basics of cellular manufacturing, including the characteristics of cells and pull systems. Includes an Interactive Lab.


Class Name:
Cell Design and Pull Systems 160
Number of Lessons:
Additional Language:

Class Outline

  • Objectives
  • Cells and Pull Systems
  • The Goals of Lean
  • Origin of Work Cells
  • Basic Cell Characteristics
  • Disadvantages of Inventory
  • Disadvantages of Push Systems
  • Advantages of Pull Systems
  • Kanban
  • Updated Kanban
  • Cell Planning
  • Cycle Time
  • Setup Reduction
  • Error Detection and Error Prevention
  • Total Productive Maintenance
  • Kaizen
  • Summary


  • Define cell.
  • Define pull system.
  • Describe the main goal of lean manufacturing.
  • Identify the combination of traditional manufacturing systems on which work cells are based.
  • Describe the characteristics of a cell.
  • Identify the disadvantages of keeping parts in inventory.
  • Identify the disadvantages of push systems.
  • Identify the advantages of pull systems.
  • Define kanban.
  • Identify modern types of kanban.
  • Describe the best method for planning work cells.
  • Define cycle time.
  • Describe the key to reducing setup time.
  • Describe how error detection applies to cellular manufacturing.
  • Describe how error prevention applies to cellular manufacturing.
  • Describe the purpose of total productive maintenance.
  • Define kaizen.

Job Roles


  • CNC Lathe Operations
  • MSSC Manufacturing Processes and Production


Vocabulary Term Definition
assembly line A linear method of manufacturing in which the object being produced passes through different work stations until it is complete.
cell A specialized grouping of people, machines, tooling, and materials. The purpose of a cell is to efficiently produce small batches of parts.
cellular manufacturing A lean manufacturing method that uses specialized groupings of machines, people, and materials.
continuous improvement Replacing ineffective practices, machines, or other manufacturing components with effective ones to attain ongoing, measurable gains. Organizations must constantly measure the effectiveness of processes and strive to meet more difficult objectives to satisfy customers.
cycle time The time that elapses from the beginning to the end of a process.
error detection The inspection of a part during and after production to determine if errors have occurred. Error detection does not try to prevent errors.
error prevention A continuous improvement method that studies why and how errors occur and looks for ways to keep them from happening again.
external customer An outside organization or individual that receives a product or service from the company.
finishing A process such as painting or sanding that is performed after a workpiece is fully constructed.
fixturing The secure clamping of a part during various machining operations.
flow shop A manufacturing facility that produces one or two similar products using high-volume specialized equipment. An assembly line is an example of a flow shop.
in-process inspection The inspection of a part during production to detect errors. Errors that are detected early may allow the part to be reworked or prevented from continuing through the manufacturing process.
intermediate fixture A workholding device that uses subplates and standardized fixtures to minimize the need for relocating after tool changeovers.
internal customer A department or individual within the company that relies on others to satisfy the external customer. For any cell, the next cell in a process is always the internal customer.
inventory Temporary or long-term storage of parts or products that are either finished or in progress. With pull systems, inventory is eliminated.
job shop A manufacturing facility that produces several different products in smaller batches. A machine shop is a type of job shop.
kaizen A Japanese word that means "change for the better." Kaizen is a combination of maintenance, problem solving, and innovation that is generally performed by a team.
kanban A Japanese word meaning "card signal." It represents any visual method used to show the need for parts or products to be moved or produced.
lean An approach to manufacturing that seeks to improve product quality and productivity, reduce cost, and eliminate waste.
linked cells A group of work cells tied together using kanban. Parts travel between cells in small batches but are fabricated one at a time within individual cells.
locating The accurate positioning of a part in relation to other known surfaces or distances.
machine shop A factory or workshop where metal is cut and shaped by machines.
milling machine A machine that uses a multi-toothed milling cutter to remove metal from the workpiece surface to create flat and angular surfaces and grooves.
pokayoke A Japanese term meaning "mistake proofing." An example of pokayoke would be a machine designed so that parts can be fixtured only in the correct position.
production kanban A kanban that contains all of the basic information about a batch, such as number and weight, plus details about what type of work should be accomplished within the cell.
project shop A manufacturing facility that produces large items, such as airplanes, by bringing the machines and materials to the project.
pull system A material management system in which parts are not delivered to machines until they are needed. Pull systems are based on actual demand for parts.
push system A production method based on keeping up with preset inventory levels or with due dates for customer orders rather than customer demand.
retooling The changing of machinery, fixtures, and tools for the production of a new part. Retooling takes place before new product runs begin.
setup reduction A lean effort that uses standardization to reduce the time it takes to perform retooling.
soldering A joining method that uses heated tin and lead to fuse parts together.
traffic The management of the movement and exchange of materials, orders, and information that takes place within a manufacturing facility.
transportation The movement of materials and parts within a manufacturing facility.
universal product code A combination of a number and a series of parallel lines, known as a bar code, that appears on consumer packaging and is used in some shops as kanban.
withdrawal kanban A kanban used to signal the movement of parts between cells. It contains just the basic information about the batch such as the number of pieces and weight.