This paper examines how 11 part-families were developed and then selected, using discrete event simulation, for cell manufacturing and subsequent exclusion from the current manufacturing system of a value added wood products company. The criteria used to exclude a family were the reduction of current average work-in-process and, secondarily, average lead times. The excluded parts could then be processed through a manufacturing cell. Using simulation and management input, two of 11 part-families, representing 51 different part types, were chosen to be excluded from the traditional job shop floor. Their exclusion resulted in an average total work-in-process reduction of 112 parts which represented a 17% reduction. A second article, in preparation, will compare the processing of the 51 parts through different simulated manufacturing cell designs.
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