What is GT?

What is GT?

 GT is a manufacturing philosophy in which similar

part are identified and grouped together to take
advantage of their similarities in manufacturing and
design.

 This group of parts or components is called part

families.
 GT Classification
based on

Grouping into Part Families Successful grouping

is key to GT
based on Implementation.
Attributes
based on

Geometric Characteristics Production Process Characteristics

Sequence NO. of Operations

SIZE SHAPE Type of Operation
determined by
Process
Holding Tooling Process
Method
Method Type Condition
 Part Families
It is a collection of part which are similar
either because of geometric shape and size
or because similar processing steps are
required in their manufacture.
The other important features that is important choosing the
families;
 Manufacturing tolerances
 Required quantities
 Materials
 Special features, which will require the use
of different machine
Process type
layout

GT
layout
 Part Families

Group technology begun by grouping parts into

families, based on their attributes.
There are three methods that can be used to
form part families:

– Manuel visual inspection

– Production flow analysis (PFA)
– Part Classification and coding system
 Manual visual inspection
Involves arranging a set of parts into groups
known as part families by visually inspecting
the physical characteristics of the parts.
Manual visual inspection limitations

– Incorrect results
– Human error
– Different judgment by different people
– Inexpensive
– Least sophisticated
– Good for small companies having
smaller number of part
 Production flow analysis
PFA is a method of identifying part families
and associated machine tool grouping by
analyzing the route sheets for parts
produced in a given shop.
It group together the parts that have similar
operation sequences and machine routings.
Part-Family Formation
 Parts classification and coding
 Large manufacturing system can be decomposed
into smaller subsystems of part families based on
similarities in part.
Part classification as per Attributes
1. Part design attributes and
2. Part manufacturing attributes
3. Both design and manufacturing attributes
 Part design attributes
 Part configuration (round or prismatic)
 Dimensional envelope (length to diameter
ratio)
 Surface integrity (surface roughness,
dimensional tolerances)
 Material type
 Raw material state (casting, forging, bar
stock, etc.)
 Part manufacturing attributes

Operations and operation sequences (turning,

milling, etc.)
 Batch sizes
 Machine tools
 Cutting tools
 Work holding devices
 Processing times
 Coding methods
 Coding methods are employed in classifying parts into part
families
 Coding refers to the process of assigning symbols to the
parts
 The symbols represent design attributes of parts or
manufacturing features of part families

 The variations in codes resulting from the way the symbols are
assigned can be grouped into three distinct type of codes:
– Monocode or hierarchical code
– Polycode or chain-type
– Hybrid or mixed code
 Monocode or hierarchical code

 The structure of monocode is like a tree in which each symbol

amplifies the information provided in the previous digit.
 It provide a relatively compact structure which
give information about part in a limited no. of digits.
 Polycode (Chain-type)
 The code symbols are independent of each symbol
in the sequence is fixed and not depend on the
preceding digit
 Each digit in specific location of the code describes
a unique property of the work piece
 it is easy to learn and useful in manufacturing situations
where the manufacturing process have to be described
 the length of a polycode may become excessive because of
its unlimited combinational features
Polycode
 MIXED CODE (HYBRID CODE)

 It is the mixture of both monocode and polycode

systems. Mixed code retains the advantages of both
systems. Most coding systems use this code structure.
 A code created by this manner would be relatively
more compact than a pure attribute code while
retaining the ability to easily identify parts with
specific characteristics.
Parts Classification and Coding Systems

 Part classification and

coding systems which are
widely recognized
among people familiar
with GT:

1. OPTIZ system
2. MICLASS system
3. CODE system
 The OPITZ classification system

 It is a mixed (hybrid) coding system

 Developed by Opitz, Technical University of
Aachen, 1970
 It is widely used in industry
 It provides a basic framework for understanding the
classification and coding process
 It can be applied to machined parts, non-
machined parts (both formed and cast) and
purchased parts
 It considers both design and manufacturing
information
The Opitz coding system consists of three
groups of digits:

Form Supplementar Secondary

code y code code
12345 6789 ABCD

part geometry and information Production

features relevant to relevant to processes and
part design manufacturing production
(polycode) sequences
Optiz Coding and Classification System
 MICLASS System

– MICLASS = Metal Institute Classification

System
– Consists of two major sections (segments)
– First segment is mandatory-total of 12 digits
– First 4 digits describe main shape and
their elements
– Second 4 digits describe dimensions ...
MICLASS System

Material code

Tolerance code

Auxiliary dimension
Dimension ratio

Main dimension
Position of shape & element
Shape
element
Main Shape
MICLASS System
 The KK-3 System
 It was originally developed by the Japan Society for Promotion
of Machining Industry. The domain is machining and grinding
parts
The KK-3 System
 COAD System

 The CODE system is a part classification and coding system

developed and marketed by Manufacturing Data
System(MDSI).
 The CODE number has eight digits.
 For each digit there are 16 possible values which are used to describe
the part’s design and manufacturing characteristics.
 [1]-basic geometry of part (Major Deviation of CODE).
[2&3]- information about manufacturing process.
[4,5&6]-specify secondary manufacturing process .
(threads
,grooves ,slot ,etc…)
[7&8]-indicate overall size of the part.
BENEFITS OF GROUP TECHNOLOGY

1. Engineering design

• Reduction in new parts design

• Reduction in the number of drawings through standardization
• Reduction of drafting effort in new shop drawings
• Reduction of number of similar parts, easy retrieval of similar functional
parts, and identification of substitute parts
2. Layout planning

• Reduction in production floor space required

• Reduced material-handling effo
BENEFITS OF GROUP TECHNOLOGY
3. Specification of equipment, tools, jigs, and fixtures
• Standardization of equipment
• Implementation of cellular manufacturing systems
• Significant reduction in up-front costs incurred in the release of new parts
for manufacture
4. Manufacturing: process planning
• Reduction in setup time and production time
• Alternative routing leading to improved part routing
• Reduction in number of machining operations and numerical control
(NC) programming time
5. Manufacturing: production control
• Reduced work-in-process inventory
• Easy identification of bottlenecks
• Improved material flow and reduced warehousing costs
• Improved usage of jigs, fixtures, pallets, tools, material handling, and
manufacturing equipment
BENEFITS OF GROUP TECHNOLOGY

6. Manufacturing: quality control

• Reduction in number of defects leading to reduced inspection effort
• Reduced scrap generation
• Better output quality
7. Purchasing
• Coding of purchased part leading to standardized rules for purchasing
• Economies in purchasing possible because of accurate knowledge of raw
material requirements
• Simplified vendor evaluation procedures leading to just-in-time
purchasing
8. Customer service
• Accurate and faster cost estimates
• Efficient spare parts management, leading to better customer service.