Last updated on
July 10, 2009

Background: Century (CFI) is a successful producer of a full line of high-end furniture with plants located in Hickory, NC. The company has undertaken a program to restructure their manufacturing philosophy to improve customer service and quality while reducing manufacturing costs.

Situation: In 1996 CFI determined that the parts machining operation in their Hickory chair plant was an ideal candidate for restructuring. The existing machine room layout was a traditional process style with like machines being grouped together and using factory trucks for moving loads between operations. The product line ranged from basic contract-type chairs to complex, high-styled dining room chairs.

CFI engaged A. G. Raymond & Company to assist in developing a new layout which contained "cells" of machinery dedicated to producing specific parts families. This task involved four major steps:

1. identifying the parts families which could be isolated into separate machine "cells" based on machine sequence
2. determining the machine loads for each "cell"
3. selecting the best materials handling devices for the parts and sub-assemblies
4. designing the layout for each "cell" and the overall machine room to minimize materials handling

The first step involved an analysis of routings for the various parts in the product line. This analysis enabled the project team to identify the machines required for each family.

Next the loads for each machine type was calculated based on the target output of the plant. From this calculation the team listed the quantity of each machine type required in each "cell".

Replacing factory trucks was an objective of the project. To streamline flow through the "cells" the team wanted a part to be machined simultaneously at two or three machines in its routing. This goal required an order to be divided into two or more loads rather than transported on a single pallet or truck. Also chair parts, being small and odd-shaped, could not be easily stacked. Plastic tote bins were selected as an ideal device for these parts and sub-assemblies. The totes are moved on a non-powered roller conveyor system with fixed roller section at the machines and track-guided transfer carts used to move loads between operations.  (Click here to view related photos)

After selecting the handling system, the team redesigned the flow in the machine room by grouping the "cells" to minimize travel distances from the first "cell" to assembly and between "cells" which needed to share machines.