Introduction to Production Systems

Introduction to Production Systems

• Manufacturing is the process of turning raw materials into finished goods using tools, human labor, machinery, and chemical processing.
• Before the Industrial Revolution, most products were handcrafted using basic tools and human labor.
• Industry 4.0 is the fourth phase of the Industrial Revolution, focused on interconnectivity, automation, machine learning, and real-time data.
• Interconnected machines and processes in manufacturing are changing how business is conducted today.

Industrial Revolutions

• Industry 1.0 (late 1700s): Mechanization using water and steam increased production capacity.
• Industry 2.0 (early 1900s): Electrification enabled mass production with assembly lines.
• Industry 3.0 (1970s onwards): Automation through electronics and computers replaced some manual tasks with automated robotic systems.
• Industry 4.0 (present): Cyber-Physical Systems (CPS) and Internet of Things (IoT) merge physical, digital, and virtual environments.

Industry 4.0 Related Technologies

• Industry 4.0 is the digital transformation of manufacturing.
• Real-time data and insights support smarter and faster decisions.
• Big Data, Additive Manufacturing, Autonomous Robots, Simulation, System Integration, Cloud Computing, and Cybersecurity are all part of Industry 4.0.

What is Technology?

• Technology encompasses methods, systems, and devices resulting from scientific knowledge used for practical application.
• Technology leverages scientific principles to change environments and advance industries.

What is a Product?

• A product is anything offered for purchase, use, or consumption intended to satisfy a want or need.

A Part, Subassembly, and Assembly

• An assembly is comprised of two or more subassemblies to conduct a certain function.
• Subassemblies are components of a larger assembly.
• Pieces are assembled to form functional products.

Manufacturing Process

• Manufacturing involves the transformation of raw materials into finished products.
• Key elements include machinery, tools, and labor processes.
• Raw materials undergo processing via manufacturing methods to produce finished goods.
• Processed materials, scrap, and waste result from the manufacturing process.

Product Design and Concurrent Engineering

• Design and manufacturing can be conducted simultaneously rather than sequentially, in Concurrent Engineering.
• Product life-cycle stages typically include start-up, rapid growth, product maturity, and decline.
• The design process involves defining product needs based on market research, conceptual design and evaluation, design analysis, prototype production and testing, production drawings, material and equipment specifications, pilot production, inspection, and quality assurance.

Product Life Cycle (PLC)

• Products have a life cycle with stages like start-up, rapid growth, maturity, and decline in demand.
• Technology, consumer trends, and market conditions influence product demand.

Role of Computers in Product Design

• Computer-aided design (CAD) and computer-aided engineering (CAE) simplify product models.
• CAD systems support rapid and thorough design analysis.
• Paperless design and performance analysis of structures are made possible.

Prototypes

• Prototypes are physical models of individual components or products.
• Rapid prototyping employs advanced technologies for quick prototyping.
• Prototypes can be reviewed for possible design modifications.

Design for Manufacture, Assembly, Disassembly, and Service (DFM/DFA/DFD)

• Design for manufacture ensures efficiency and accuracy in the production process.
• Incorporating multiple technologies and techniques for manufacture, assembly, and disassembly.
• Analyzing components for their ease of assembly, speed of assembly, and cost of assembly.

Green Design and Manufacturing

• The manufacturing process is designed with environmental concerns in mind.
• Environmental impacts from materials, processes, activities, and product designs should be considered.
• Sustainable design and manufacture minimize waste and promote recycling.
• Utilizing renewable energy, responsible use of materials, and efficient manufacturing procedures help sustain ecosystems.

Selection of Materials

• Material availability, production schedules, and resource self-reliance are factors in material selection.
• The proper service life of a product depends on factors like material selection, production methods, and maintenance.
• Material properties (mechanical, physical, chemical, manufacturing, and appearance) inform material selection.

Selection of Manufacturing Processes

• Various methods for shaping metals (casting, forming), processing polymers (extrusion, molding, thermoforming), machining, joining, and finishing.
• Selection is determined by manufacturing requirements that include geometric features of the parts.

Net-Shape and Near-Net-Shape Manufacturing

• Net-shape manufacturing creates products with desired dimensions and surface finishes during a single operation.
• Near-net-shape manufacturing closely approximates final product dimensions.
• Geometric characteristics of the part will help ascertain the most appropriate manufacturing process.

Types of Production

• Production methods are classified based on volume/variety (job shop, batch, mass, continuous).
• Job shops produce small batches, mass production produces high volumes, and continuous methods produce highly repetitive products.

Computer Integrated Manufacturing (CIM)

• CIM integrates computers throughout the manufacturing process.
• CIM facilitates production changes and improves worker/machine efficiency.
• Control of production and management are improved with CIM.

Quality Assurance and Total Quality Management

• Building product quality through consistent processes at every step.
• Quality assurance (QA) involves a thorough evaluation and oversight during manufacturing.
• Total quality management (TQM) emphasizes overall quality through teamwork involvement.

Lean Production and Agile Manufacturing

• Lean manufacturing focuses on minimizing waste while maximizing efficiency during production.
• Lean production focuses on each activity, including efficiency and effectiveness of machinery, equipment, and workers.
• Agile manufacturing adapts quickly to altering customer demands and changing market conditions.

Manufacturing Costs and Global Competition

• Manufacturing costs are a crucial part of pricing, production planning, and financial performance.
• Material, labor, and other costs affect international competitiveness in the global manufacturing sector.