37092590 Manufacturing Process Intro to Manufacturing

8/7/2019 37092590 Manufacturing Process Intro to Manufacturing

http://slidepdf.com/reader/full/37092590-manufacturing-process-intro-to-manufacturing 1/34



Group No-3ROLL NO

Priyank Rathod

35 Asif Shaikh 41

Ayesha Shaikh

42Falguni Sharma

44Pravin Wadhwana

49



1INTRODUCTION TO MANUFACTURING

cturing activities must be responsive to several demands and trends:



2INTRODUCTION TO MANUFACTURING



DEFINITION OF MANUFACTURINGDEFINITION OF MANUFACTURING 3

What is manufacturing?

“the process of converting raw materials into products”.

e word “manufacturing” is derived from the Latin manu factus, meaning madehand.

“the conversion of stuff into things” – (by DeGarmon, 1998).

rocessing or making a product from raw materials, especially as a large scale

eration using machinery” – (by Collin English Dictionary, 1998).

conomic term for making goods and services available to satisfy customer”(by T.Black, 1991).



4MANUFACTURING In modernIn modern

context context

he making of products from raw materials using various processes,uipments, operations and manpower according to a detailed plan”.

ring processing, the raw material undergoes changes to allow it to become

rt of a product(s).

Once processed, it should have worth in the market or a value.

- Therefore, it encompasses:

- The design of the product.

- The selection of raw materials.- The sequence of processes through which the product will be manufactured

ord production is often interchangeably with word manufacturing.



5MANUFACTURING PROCESS

Manufacturing can be defined two ways:Technology – manufacturing is the application of physical and chemicalocesses to alter the geometry, properties, and/or appearance of a givenrting material to make parts or products.

nufacturing also includes the assembly of multiple parts to make products.

) Economic – manufacturing is the transformation of materials into items of reater value by means one or more processing involve. Therefore,anufacturing is “added value” to the material.

The processes to accomplish manufacturing involve a combination of machinery, tools, power, and manual labor.

- “Added value” – by changing the material’s shape or properties or bycombining it with other materials that have been similarly altered.




Two ways models to define manufacturing:

1) As a technical process

ManufacturingProcess

Raw materials

Product

Profit

M

a c

h i n

e r y

T o o

l i n g

P o w e r

L a

b o r




2) As an economic process.

ManufacturingProcess

Valueadded

Startingmaterial

Material inprocessing

Processedmaterial



8Types Of Industries

Industries can be classified as:



9Types Of Industries

Types of industriesTypes of industries

1) Primary industry

Those that cultivate and exploit natural resources; eg: agriculture, mining.

2) Secondary industry

Take the outputs of the primary industries and convert them into consumer anapital goods.

3) Tertiary industry - Constitute with service sector of the economy.



10TYPE OF MANUFACTURINGTYPE OF MANUFACTURING

OPERATIONSOPERATIONS

YPE OF MANUFACTURING OPERATIONSYPE OF MANUFACTURING OPERATIONS

1) Project – 1 to 10 units.

2) Job shop – 10 to 100 units.

3) Batch – 100 to 10,000 units.

4) Mass – Above 10,000 units.

uction quantity:uction quantity: number of unit produced annually of a particular product

type.

uct variety:uct variety: different product designs or types that are produced in the plant.

[Low production]

[Medium production] [High production]





Low

Medium

High

Product quantityProduct quantity





Project

Job shop

Batch

Mass

Product variety Product variety

1 to 10 units

10 to 100 units

100 to 10,000 units

Above 10,000 units





1) PROJECT1) PROJECT

Product position – remains stationary during the manufacturing process – size,eight, location of the product.

- Materials, people, machinery are brought to the product or product site.

- Example: bridge, building construction, aircraft, ships, locomotive.

- Based on customer specifications.





2) JOB SHOP2) JOB SHOP

Low volume and production quantities called lot sizes with high product variety

- Satisfies a market for nonstandard or unique product.

Layout – different machines with similar functional or processing capabilitiesre grouped together as department.

Require high skill levels labor – to operate a variety of equipments.

Example: space vehicles, reactor vessels, turbines, aircraft components.

- A short duration activities to provide custom goods.





3) BATCH3) BATCH

Batch production produce or process any product in groups which is calledbatches”.

Can produce a variety of products – opposed to a continuous productionrocess, or a one time production.

xample: Similar standard items made periodically in batches: bakery, paint,

nd tools.

- Same facilities used to manufacture all the different items.

Useful for industries that makes seasonal items/products for which it isifficult to forecast the demand.

Layout of machine – functional layout (based on its function to be performed –om section to another section).





4)4) MASSMASS

Also known as flow production, repetitive flow production, series production.

Machinery (e.g.: robots, machine press) that is needed to set up the massroduction line is so expensive.

- Involved fewer labor cost and a faster rate of production.

roducing goods in large quantities at low cost per unit and produce in a short

riod of time.

- Plant and equipments are arranged in a flow line layout.

peration is done base on specific product and thus make the productionntrol easily.

Work piece is transfer automatically from one machine to another.

- Example: light bulbs, refrigerator, tv.



17MANUFACTURING Operation

AdvantagesAdvantages

educe initial capital outlay – due to a single production line can be used toveral products – machines can be used more effectively, materials can beught in bulk, workers can specialize in that task.

DisadvantagesDisadvantagesequires very careful production planning & control – next batches; when, types

hen switching to another batches – takes time (“down time”) – can causess of output (low yield).

esulted “WIP” or create inventory/stock – increases costs such as inventoryst, cost because of damage to stock.



18MANUFACTURING OPERATION

The example production line (shown below) is that of an engineering company, manufacturing small

steel products such as hinges and locks. They manufacture batches of five hundred at a time. Theworkers are unskilled and semi skilled. As each task is completed the item being manufactured ispassed down the production line to the next worker, until it is complete.



19Lean Production and AgileLean Production and Agile

ManufacturingManufacturing

Lean ProductionLean Production

systematic approach to identifying and eliminating waste in manufacturing

cess through continuous improvement by following the product at theand of the customer.

lated to a word “less”: less time, inventory space, people, developing theduct, – minimize the cost.

It is all about “speed” and getting it right at the first time.





Benefits of Lean Manufacturingenefits of Lean Manufacturing

- Overhead operating costs reduces by 30%.- Sales ($) per employee 10 times higher.- Profits 4 times.- Lead time cut by 50% to 90%.- Process queues cut by 70%.

Principle of Lean Manufacturingrinciple of Lean Manufacturing

- Voice of the customer.

- Continuous improvement.

- Recognize & eliminating waste of:- Over production.

- Inventory.

- Defects (Non-zero defect rates).





AGILE MANUFACTURING AGILE MANUFACTURING

ile manufacturing is a term applied to an organization that has created thecesses, tools, and training to enable it to response quickly to customer needs arket changes while still controlling costs and quality.

he implementation of the principles of lean production on a broad scale.



tends to simplify and break the whole system into small, autonomous units.

23JUST IN TIME (JIT)

JUST IN TIME (JIT) JUST IN TIME (JIT)

aw materials, parts & components are delivered to the manufacturer just ine to be used, parts & components are produced JIT to be made into

assemblies & assemblies, and products are finished JIT to be delivered tocustomer.

- JIT is also known as “pull system”.




Benefit s/Advantages of JITBenefit s/Advantages of JIT

- Low inventory – carrying cost.

st detection of defects in the production or the delivery of supplies and, hence,scrap loss.

- Reduced inspection and reworking of parts.

- High quality products made at low cost.

- Reduction of :

60% to 80% in inventory.

Up to 90% in rejection rates.

90% in lead times.

50% in scrap & rework.

20% to 40% in productcost.




enefit s/Advantages of JIT (cont’)enefit s/Advantages of JIT (cont’)Increases:

- 30% to 50% in labor productivity.

KANBAN SYSTEMKANBAN SYSTEM

Integrated with the implementation of JIT concept.

- Kanban – means “visible record”.

Originally consisted of two types of cards:

Production card: authorizes the production of one container or cart of identica

specified parts at a workstation.

Conveyance/move card: authorizes the transfer of one container or cart of parfrom that particular w/station to the w/station where the parts will be used.




KANBAN SYSTEM (cont’)KANBAN SYSTEM (cont’)

The cards contain information on:

i) Type of parts.

ii) Location where issued.

iii) Part number.

iv) Number of items in container.



27TYPES OF LAYOUT

1) FIXED POSITION LAYOUT1) FIXED POSITION LAYOUT

nvolved with huge parts; eg: construction of aeroplane, bridge, buildings.

ll resources such as manpower, raw materials, tools, machinery and etc will beught to the product.

- Involve with longer lead time.



28TYPES OF LAYOUT

2) FUNCTIONAL (PROCESS) LAYOUT2) FUNCTIONAL (PROCESS) LAYOUT

- Plant grouped according to type of process.

- Specialization of skills.

- Higher machine utilization.

- Queues of work.

- Longer lead times.

- Flexibility of operation.

- Low volume and high variety of manufacturing.



29TYPES OF LAYOUT

) FLOW LINE (PRODUCT) LAYOUT) FLOW LINE (PRODUCT) LAYOUTPlant arrangement to facilitate material processing in the same order.

- Machines and equipment are positioned along a flow line.

Product passes from workstation to another workstation along the flow line.

- Suitable for mass production system.

Several flow lines may come together to feed the final assembly line.

Need to categorize operations to ensure equal processing time at all work statiine balancing).

- High level of machine and manpower utilization.



30TYPES OF LAYOUT

4) CELLULAR LAYOUT4) CELLULAR LAYOUTlant divided into groups or cells in a small unit (individual cell), consisting of overal workstations.

A w/station can contains either one machine (known as a single machine cell),everal machines (known as a group machine cell) with each machine performin

ifferent operation on the part.

Cells can process a complete family of parts – need to form families of product

he flow among the equipment in the cells can vary depending on the composirts within the part family.

ood example for the implementation of the concept of group technology.

he machines at w/stations can be modified, retooled, and regroup for differentoduct lines within the same family of parts.



AdvantagesAdvantages

31TYPES OF LAYOUT

- Reduced work handling leads to short cycle time/piece.

- Less WIP.

- Simple planning and control.

- Reduced labor skill.

- Good space utilization.

DisadvantagesDisadvantages

- Limited flexibility.

- Machine breakdown causes major problem.

- High setting up cost.- Uses expensive special purpose machine.

37092590 Manufacturing Process Intro to Manufacturing

Documents

Transcript of 37092590 Manufacturing Process Intro to Manufacturing