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alvarez_thesis - DESIGN AND IMPLEMENTATION OF CELLULAR...

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DESIGN AND IMPLEMENTATION OF CELLULAR MANUFACTURING IN A JOB SHOP ENVIRONMENT by Liana María Alvarez López B.S., Naval Architecture and Marine Engineering, Massachusetts Institute of Technology, 1987 M.S., Naval Architecture and Marine Engineering, Massachusetts Institute of Technology, 1993 Submitted to the Sloan School of Management and the Department of Mechanical Engineering in Partial Fulfillment of the Requirements for the Degrees of Master of Business Administration and Master of Science in Mechanical Engineering in Conjunction with the Leaders for Manufacturing Program at the Massachusetts Institute of Technology May 1997 1997 Massachusetts Institute of Technology Signature of Author Sloan School of Management Department of Mechanical Engineering May 23, 1997 Certified by Professor Eugene E. Covert, Thesis Advisor Department of Aeronautics and Astronautics Certified by Professor Stephen C. Graves, Thesis Advisor Sloan School of Management Accepted by Professor Ain Sonin, Chairman, Graduate Committee Department of Mechanical Engineering Certified by Larry Abeln, Director of Master’s Program Sloan School of Management
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3 Design and Implementation of Cellular Manufacturing in a Job Shop Environment by Liana María Alvarez López Submitted to the Sloan School of Management and the Department of Mechanical Engineering in Partial Fulfillment of the Requirements for the Degrees of Master of Business Administration and Master of Science in Mechanical Engineering Abstract The thesis proposes a method for introducing cellular manufacturing in an operating job shop. By applying cellular manufacturing to produce part families with similar manufacturing processes and stable demand, plants expect to reduce costs and lead-times and improve quality and delivery performance. The thesis outlines a method for assessing, designing, and implementing cellular manufacturing, and illustrates this process with an example. A manufacturing cell that produces aluminum parts for commercial customers is implemented at Boeing’s Defense and Space Group Machining Center. The conclusions of the thesis highlight the key lessons learned from this process. Thesis Advisors: Professor Eugene E. Covert, Department of Aeronautics and Astronautics Professor Stephen C. Graves, Sloan School of Management
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5 Acknowledgments The author gratefully acknowledges the support and resources made available to her through the MIT Leaders For Manufacturing Program, a partnership between MIT and major U.S. manufacturing companies. I would like to express my sincere thanks to Al Koszarek and all those at Boeing who helped and encouraged me through my internship, and made the “cell” come true. The author is also grateful to her thesis supervisors, Prof. Graves and Prof. Covert, for their guidance through the internship and thesis process.
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