Manufacturing Systems- Lesson 2
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Transcript of Manufacturing Systems- Lesson 2
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8/3/2019 Manufacturing Systems- Lesson 2
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Manufacturing Systems
Selection of Manufacturing Systems
It must be able to meet thespecifications set for the final product
It must be cost effective
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Manufacturing Systems
Selection of Manufacturing Systems
The product specifications can be met using
the right technology, but that is always notthe case.
Since stricter specifications add to the costof the product, there is always a trade off
between the desired specifications and thecost to achieve such specifications.
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Manufacturing Systems
Selection of Manufacturing Systems
Factors affecting the choice of ManufacturingSystems
Effect of Volume/ Variety
Capacity of the plant
Flexibility
Lead time
Efficiency
Environment
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Manufacturing Systems
Selection of Manufacturing Systems
Effect of Volume/ Variety
One of the major consideration in the processselection is the Volume Variety of the product(s).
i.e. number of products vs. variety
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Manufacturing Systems
Selection of Manufacturing Systems
Effect of Volume/ Variety
High Product Variety needs
Highly skilled labour
General purpose machines
Detailed and sophisticated production planningand control systems
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Manufacturing Systems
Selection of Manufacturing Systems
Effect of Volume/ Variety
Low Product Variety needs
Low skilled labour
Highly automated mass production systems withspecial purpose machines
Simple production planning and control systems
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Manufacturing Systems
Selection of Manufacturing Systems
Capacity of the Plant
The decision depends on
Projected Sales volume
This decides whether the production processshould be intermittent or continuous.
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Manufacturing Systems
Selection of Manufacturing Systems
Capacity of the Plant
Fixed costs are high for continuous processand low for intermittent process while variablecosts are more for the intermittent process andless for continuous process.
Intermittent process therefore will be cheaperto install and operate at low volumes andcontinuous process will be economical to useat high volume.
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Manufacturing Systems
Selection of Manufacturing Systems
Flexibility
Flexibility implies the ability of the company to satisfy
varied customers requirements. Flexibility andproduct variety are inter-related. If more variety is tobe manufactured, the manufacturing facilities willhave to be commonised (generalised) and dependingupon the volume, the extent of commonalities willrequire to be justified.
Greater commonalities demands intermittentmanufacturing which is associated with higherinventories, large manufacturing lead times andelaborate planning and control.
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Manufacturing Systems
Selection of Manufacturing Systems
Lead Time
Lead times more appropriately called delivery lead
times expected by the customers (i.e. how soon thedemand has to be met without losing on sales) isanother major influencing factor in a competitivemarket. As a general rule, faster deliveries areexpected in a competitive market.
The product, therefore, may require to be produced tostock using principles of batch production/massproduction.
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8/3/2019 Manufacturing Systems- Lesson 2
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Manufacturing Systems
Selection of Manufacturing Systems
Efficiency
Efficiency measures the speed and the cost of the
transformation process. Efficiency is greatest whenthe product is mass produced.
But to mass produce a product, greater salesvolumes are required.
Therefore, depending upon the sales volume, product
variety will have to be considered and the processwhich will give the best efficiency in terms of machineand manpower utilization will have to be selected.
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8/3/2019 Manufacturing Systems- Lesson 2
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Manufacturing Systems
Selection of Manufacturing Systems
Environment
Environment brings in new technologies and forces the
adoption of new process of manufacturing.
For example, wooden furniture is gradually being replacedby metals and plastic. So a furniture manufacturing unit willhave to change its technology
(i.e. change from one off production to batch production)
to fall in line with changing times. Similarly, as marketpreferences change due fashions or other reasons, themanufacturing process has to be changed accordingly.
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8/3/2019 Manufacturing Systems- Lesson 2
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Manufacturing Systems
Types of ManufacturingSystems
Project Production Jobbing Production
Batch Production Mass & Flow Production
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Manufacturing Systems
Types of Manufacturing Systems
Project Production
A single assignment of complex nature isundertaken for completion in a givenperiod within the estimated expenditure.
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Manufacturing Systems
Types of Manufacturing Systems
Jobbing Production
One or few units of a product isproduced as per the customersspecification in a given time and cost.
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Manufacturing Systems
Types of Manufacturing Systems
Batch Production
Limited quantity of multiple productsare produced but only one product ata time.
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Manufacturing Systems
Types of Manufacturing Systems
Mass & Flow Production
Production run is conducted on one ormultiple machines, arranged in thesequence of production operation and highvolumes of the product are produced at atime and stocked in warehouses, awaitingsale.
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Manufacturing Systems
Types of Manufacturing Systems
Process Production
Production run is continued for anindefinite period.
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Manufacturing Systems
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Type of Production
IntermittentProduction
ProjectProduction
JobbingProduction
BatchProduction
ContinuousProduction
Mass & FlowProduction
ProcessProduction
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Manufacturing Systems
Project ProductionCharacteristics
Definite beginning and definite endNon-uniform requirement of resources Involvement of different agencies Fixed Position LayoutHigh cost overruns Personnel problems Scheduling and control
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Manufacturing Systems
Project Production
Characteristics
Definite beginning and definite end
Each project has a fixed timeline
for execution.
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Manufacturing Systems
Project ProductionCharacteristics
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Non-uniformrequirement of resourcesRequirement for resources in a project is non-uniform.Generally at the completion of a project, the resources areredeployed elsewhere.
Even during the life of the project, the resource requirement isnot uniform.
Generally, at the beginning of a project, the resource reqs. arelow, which builds up as the project progresses and once againthe requirement goes down when the project faces completion.
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Manufacturing Systems
Project ProductionCharacteristics
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Involvement of different agencies
A project generally involves many tasks, each having aspecialty and that calls for the involvement of multipleagencies.
The tasks follow a strict precedence.
As a result of that, co-ordination between the agencies are ofutmost importance.
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Manufacturing Systems
Project ProductionCharacteristics
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Fixed Position Layout
Where the output of a project is a customized product, suchkind of operations are complex and are generallycharacterised byimmobilityduring transformation. Such types of operationsare carried out in Fixed Position assembly type layout. This
can be observed in production of Ship, locomotive, buildingsetc.
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Manufacturing Systems
Project ProductionCharacteristics
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High cost over runs
Often delays take place in the completion of the projects. Suchdelays are generally expensive due to escalation of the costfactors and also penalties.
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Manufacturing Systems
Project ProductionCharacteristics
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Personnel Problems
Project production has various personnel related problems.
When there is a fast buildup, staff is either borrowed fromother departments or hired for short duration. Therefore,personnel involved in the project have limited interest in the
project.Since each project ha limited duration, the staff starts gettingprepared for the next project before the completion of theongoing project.Site of the project may be in an underdeveloped region,thereby causing personnel related problems.
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Manufacturing Systems
Project ProductionCharacteristics
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Scheduling & Control
Due to the large number of activities, involvement of differentagencies and strict precedence requirements, scheduling andcontrol assumes acute importance.
Some network planning techniques like PERT and CPM
proves to be quite useful for the said type of production.