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FundamentalsofManufacturingSystems

http://studygalaxy.com/

Production is the transformation process of materials ofnature into articles of use to mankind using machine,tool and labor on a large scale.

If other supporting activities such as quality control,scheduling production planning, etc. are consideredalong with production process, its known asManufacturing.

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Production & Manufacturing

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The manufacturing system of an organization is that partwhereby resources, flowing within a defined system, arecombined and transformed in a controlled manner to add value inaccordance with the policies communicated by management.

The manufacturing system has the following characteristics:

1. Manufacturing is an organized activity, so every manufacturingsystem has an objective.

2.The system transforms the various inputs to useful outputs.3. It does not operate in isolation from the other organization

system.4. There exists a feedback about the activities, which is essential to

control and improve system performance.

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Manufacturing System

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A manufacturing system consists of severalcomponents:

1.Production machines plus tools, fixtures & other relatedhardware,2.Material handling system,3.Computer systems to coordinate and/or control theabove components,4.Human workers.

Components of a Manufacturing System

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Schematic of a Manufacturing System

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Evolution

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1945-1965

• MassProductionEra

• Seller’smarket

1965-1975

• InventoryControl Era

• Costmanagement

1975-1990

• QualityControl Era

• Leanmanufacturing

1990onwards

• FlexibleManufacturing

• Consumersatisfaction

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Job ShopManufacturing System

Batch TypeManufacturing System

Mass ProductionManufacturing System

CellularManufacturing System

FlexibleManufacturing System

Computer IntegratedManufacturing System

Job shop systems are characterized by manufacturing of one orfew quantity of products designed and produced as per thespecification of customers within prefixed time and cost.

Characteristics:The Job-shop manufacturing system is followed when there is:

1.High variety of products and low volume.2.Use of general purpose machines and facilities.3.Highly skilled operators who can take up each job as achallenge because of uniqueness.4.Large inventory of materials, tools, parts.5.Detailed planning is essential for sequencing the requirementsof each product, capacities for each work center and orderpriorities.

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#1#1 -- JOB SHOP Manufacturing SystemJOB SHOP Manufacturing System

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Advantages:Following are the advantages of job shop system:1.Because of general purpose machines and facilities variety ofproducts can be produced.2.Operators will become more skilled and competent, as each jobgives them learning opportunities.3.Full potential of operators can be utilized.4.Opportunity exists for creative methods and innovative ideas.

Limitations:Following are the limitations of job shop system:1.Higher cost due to frequent set up changes.2.Higher level of inventory at all levels and hence higher inventorycost.3.Production planning is complicated.4.Larger space requirements.

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Batch manufacturing is defined by American Production andInventory Control Society (APICS) “as a form of manufacturing inwhich the job passes through the functional departments in lots orbatches and each lot may have a different routing.” It ischaracterized by the manufacture of limited number of productsproduced at regular intervals and stocked awaiting sales.

Characteristics:Batch manufacturing system is used :1.When there is shorter production runs.2.When plant and machinery are flexible.3.When plant and machinery set up is used for the production ofitem in a batch and change of set up is required for processing thenext batch.4.When manufacturing lead time and cost are lower as compared tojob order production.

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#2#2 -- BATCH Manufacturing SystemBATCH Manufacturing System

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Advantages:Following are the advantages of batch production:1.Better utilization of plant and machinery.2.Promotes functional specialization.3.Cost per unit is lower as compared to job order production.4.Lower investment in plant and machinery.5.Flexibility to accommodate and process number of products.6.Job satisfaction exists for operators.

Limitations:Following are the limitations of batch production:1.Material handling is complex because of irregular and longerflows.2.Production planning and control is complex.

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Manufacture of discrete parts or assemblies using a continuousprocess are called mass production.

Characteristics:Mass production is used under the following circumstances:1.Standardization of product and process sequence.2.Dedicated special purpose machines having higher productioncapacities and output rates.3.Large volume of products.4.Shorter cycle time of production.5.Lower in process inventory.6.Perfectly balanced production lines.7.Flow of materials, components and parts is continuous andwithout any back tracking.8.Production planning and control is easy.9.Material handling can be completely automatic.

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#3#3 –– MASS Production Manufacturing SystemMASS Production Manufacturing System

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Advantages:Following are the advantages of mass production:1.Higher rate of production with reduced cycle time.2.Higher capacity utilization due to line balancing.3.Less skilled operators are required.4.Low process inventory.5.Manufacturing cost per unit is low.

Limitations:Following are the limitations of mass production:1.Breakdown of one machine will stop an entire production line.2.Line layout needs major change with the changes in the productdesign.3.High investment in production facilities.4.The cycle time is determined by the slowest operation.

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#4#4 -- CELLULAR Manufacturing SystemCELLULAR Manufacturing SystemRather than route the materials required through the entire plant,materials flow to the head of each work cell, through each processin the cell, then to final assembly. This eliminates most of thetransportation and waiting we would see in the traditionalapproach.

Cellular manufacturing system is based on the concept of grouplayout.

Fixed Position Layout- All resources are brought at the job site.Process Layout- Have different processing stations & job isbrought at those stations.Product Layout- Single piece flow of product through a sequenceof machines placed as per product requirement.Group Layout- combination of process & product layout, in cells.

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C2

C3

M1

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M2

M4M1

M2M1

M3M2Raw material Product

C1

Characteristics:1.Combination of product & process layout.2.The jobs are clubbed which are having similar properties.3.One part family produced at one place.4.Less material handling.

A Flexible manufacturing system is a configuration of computercontrolled, semi-independent workstations where materials areautomatically handled and machine loaded. FMS is a type offlexible manufacturing system that builds on the programmableautomation of NC and CNC machines.

Characteristics:1.It contains several work stations, each performing differentoperation.2.The work stations and machines are automated.3.More variety of products as per consumer requirements.4.Fast processing of products.5.It is expensive in setting up.

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#5#5 –– FLEXIBLE Manufacturing SystemFLEXIBLE Manufacturing System

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Advantages:Following are the advantages of flexible manufacturing system:1. More variety of products can be produced to cope up with

consumer demand.2. Better quality products.3. Complex parts can be finished in one setting.4. Reduction in non-productive & time lead time.5. Save labor cost.

Limitations:1. High setup cost.

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Computer Integrated manufacturing is an interdisciplinary scienceapplied to manufacturing. It involves the amalgamation ofinformation science with automated manufacturing.

“CIM is the integration of the total manufacturing enterprisethrough the use of integrated systems and data communicationscoupled with new managerial philosophies that improveorganizational and personnel efficiency.”

- By the Computer and Automation SystemsAssociation of the Society of Manufacturing Engineers

(CASA/SME).

#6#6 –– Computer Integrated Manufacturing SystemComputer Integrated Manufacturing System

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Future trends include:-1.AGILE Manufacturing2.GREEN Manufacturing3.VIRTUAL Manufacturing4.The JUST-IN-TIME or KANBAN Approach

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# ADVANCED Manufacturing Technology# ADVANCED Manufacturing Technology

Agile Manufacturing…Agile manufacturing has been called the 21st-century

manufacturing enterprise strategy.By Agile, we mean the firm can quickly respond to market

changes by quickly reengineering its business processes,reconfiguring its manufacturing systems, and innovating itsproducts.

Green Manufacturing…Green manufacturing aims at developing a manufacturing

paradigm and methods for reducing pollution by amanufacturing firm.

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Virtual manufacturing… By using virtual reality and high-performance simulation,

virtual manufacturing focuses on building a digital modelof the product and studies the dynamic and kineticperformance of the product to reduce productdevelopment cost and time.

Just-in-Time or Kanban Approach…The objective of this recent trend in material control is to

reduce the need for large, expensive inventories ofmaterial and sub-assemblies.By requiring that external and internal suppliers deliver

just the right items, at just the right place, at just the righttime, this objective may be met.

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The Ford Motor Co.The Ford Motor Co.and Mass Productionand Mass Production

CASE STUDY:

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Ford’s early production was increasing asfast as they could build cars

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Time required to build a car reduced with time byimprovement in their manufacturing systems

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Mass Production at Ford, 1907Mass Production at Ford, 1907 -- 19321932Key points:

“In mass production there are no fitters” - Henry Ford. Stamping plays important role in providing low cost highprecision parts.Constant improvement, division of labor, standard work, flatorganization. Moving assembly line (1913) comes from otherexamples in industry. Work pace is increased and turnover rateincreases. In late 1913, to add 100 workers Ford needed to hire 963people. $5/day pay is instituted to address this problem.Vertical integration is taken to limits at River Rouge. End ofprevious cost cutting strategy, conveyor system limits flexibility,labor strike moves Ford to build new plants at other locations.Conversion from Model T to Model A is too late and extremelypainful, occasions 6 month shut down and great upheaval.GM introduces yearly model change 1925-1932.

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Common elements betweenCommon elements betweenFord and “Lean”Ford and “Lean”

Elimination of WasteEquipment Placed in the Sequence ofOperationsReduced InventoryProduction to Demand not to StockContinuous ImprovementFlat Organization

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A Control Theorist's Perspective On Recent Trends In ManufacturingSystems, Stanley B. Gershwin, Richard R. Hildebrant , Rajan Suri , SanjoyK. Mitter, 23rd IEEE Conference On Decision And Control, Las Vegas,Nevada

Advanced Manufacturing Technology , Module 5.2 ManufacturingMetrics, R.Siriram, January 2006.

Hiltomi, Manufacturing System Engineering, Tailor & Francis.

David A. Hounshell, From the American System to Mass Production,1800-1932, The John Hopkin’s University, Press, 1984.

Karl Williams, Colin Haslam and John Williams; ‘Ford versus Fordism,The Beginning of Mass Production?’; Work, Employment and Society,December 1992.

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REFERENCESREFERENCES::

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