Manufacturing System Optimization

• Presents integrated manufacturing systems and their impact on business and industry, focusing on economic and practical considerations.
• Highlights the importance of planning, administration, continuous improvement, and enhancement in manufacturing systems for organizational productivity and competitiveness.
• Discusses execution as a competitive advantage achieved through optimal manufacturing system design and control, integrating computer use.
• Explains the transformation of inputs into finished products through activities, operations, and processes, noting the varying manufacturing systems across industries.
• Covers manufacturing planning as a key element of a successful model, including planning activities, manufacturing control for real-time monitoring, and process planning.
• Explores group technology, its background, advantages, and disadvantages, and its role in revolutionizing manufacturing in the 21st century.
• Emphasizes that the main objective of designing a manufacturing system is optimizing production while considering raw materials, equipment, labor, and the physical plant.

Introduction to Manufacturing

• Manufacturing involves modifying raw material properties to create finished products.
• It economically adds value to materials through manufacturing or assembly processes, according to Groover (2018).
• Core components include work design, standards, and methods, which emphasizes the influence of engineers in enhancing product competitiveness through man-machine relationship, tools, and workstation design.
• Aims to produce quality products at the lowest cost, on time, with minimal capital, and ensure worker satisfaction.
• Addresses issues like product flow, scheduling, order sequencing, and adherence to schedules.
• Focuses on production volumes, timing, and determining the optimum production batch.
• Method analysis is essential for continuous improvement.

Basic Definitions of a Manufacturing System

• It's an organized system converting inputs into useful goods/services.
• Conversion happens through a productive process, ensuring the product (goods/services) differs from the raw material.
• System response depends on:
  • Input
  • Process limitations
  • External non-controllable factors
• The result of the production process is the creation of new goods/services.

Design of Activities in Manufacturing Systems

• Includes nine main analyses for a systematic approach.
• The purpose of the operation addresses its necessity, potential for elimination, or combination with another.
• Design of the parts is reviewed for improvements.
• Tolerances and specifications: Only necessary closed tolerances are used to optimize costs.
• Materials: Use the least expensive, easiest-to-process, standardized materials from the best supplier.
• Sequence and Manufacturing Process: Evaluates consequences of changes, mechanization, machines, and tools.
• Configuration and Tools: Considers the pattern/guide for construction and necessary tools and optimal tool number depends on economics.
• Material Handling aims for unit cost reduction.
• Distribution of the Plant aims to facilitate product manufacture at the lowest cost.
• Design of the Work considers ergonomics where operation adapts to the worker.

Planning and Control of Activities for Manufacturing Systems

• Activities must be planned in terms of design and usage frequency in production.

• Industrial engineering controls application and improvement.

• Main Parameter: Standard times, which are verified with periodic audits.

• Critical elements: Production and cost control.

• Production Control: Manages programming, routing, expediting, and monitoring to cut costs and meet requirements.

• The basic control method is scheduling.

• Master scheduling is a medium-term plan considering supply times and product production in advance. It adapts to demand, new products, and customers.

• Scheduling of accepted orders is a short-term program displaying the schedule against which detailed schedules are based.

• Detailed schedule of the operation or loading of machines is a short-term program showing production load detailing what needs to be made.

• The detail across the levels of production scheduling increases specificity.

• Schedules require time standards to accurately determine production flow and work in progress.

• Schedule accuracy depends on standard times, and reliability requires time standards.

• Manufacturing costs are classified into four groups:

  • Direct material cost is the unit cost of raw materials that are part of the manufactured product.
  • Direct labor cost includes only personnel transforming raw material.
  • Manufacturing expenses include non-productive inputs and energy.
  • Overhead includes all plant expenses, excluding direct costs and manufacturing costs.

• Standard cost: It is determined from manufacturing cost plus a normal variation factor. It is a goal to be achieved used for budgeting.

• Actual costs: Compare standard costs with actual costs during production.

• Variations: Determine if costs are favorable or unfavorable.

Example Manufacturing System

• A metal manufacturing company adds a new product line and requires the following:
  • Space, equipment, raw material, labor
  • Manufacturing methods, systems, and administration
  • Operating capital
• Manufacturing engineers determine the method, machinery, floor space and labor.
• The manufacturing engineers determine standard manufacturing times and costs with the finance department.
• Materials and production partner to establish schedule.
• Once installed, the machinery and initial manufacturing test begins.

Glossary

• Standard Time: Time required by a qualified worker under normal conditions
• Master Scheduling: Long-term based on customer or on market demand.
• Scheduling of Accepted Orders: Scheduling of customer order fulfilment.
• Detailed Schedule: Schedule details are assigned for machine.
• Direct Material Cost: Cost of raw materials.
• Direct Labor Cost: Cost of time used for labor.
• Manufacturing Costs: Includes direct labor, overhead, etc.
• General Costs: All costs necessary to maintain production.
• Standard Cost: Estimate of all cost elements assigned.
• Actual Cost: The cost of production determined by accounting

Conclusion

• The main element for achieving a good manufacturing system and continuous productivity improvement is consistent application methods, standards and design work.
• Operation analysis helps design and improve what needs to be done on the production floor.
• Consistency requires the inspection that the methods are being maintained.
• Measuring system efficiency leads to continuous improvement and prevents decline.

Manufacturing Planning and Control

• Manufacturing complexity is a key element that can lead to a myriad of situations that can compromise the entire process.
• Planning and control tasks are essential to maintaining correct operations.
• Activities are considered a general part of the nervous system of a manufacturing operation.
• The activities can change depend on company and industry.
• Control systems are more effective that consider these factors:
  • company size
  • control detail required
  • manufacturing processes
  • type of manufactured product.
  • Target Markets
• Computers make it possible for simple and more sophisticated manufacturing control
• A great advantage to using computers lies in the capability of handling simulation of mathemtical data.
• As AI gains prominance, it is expected that there will continue to be a revolution in manufacturing.

Procedures for the planning and control of manufacturing systems

• Order control is most common in intermittent production system companies.
• Flow control is applicable to process industries like oil, glass, food, among others.
• Programming is made when the arrangement of the plant is made.
• A balanced and sequenced production line enables easier scheduling and control.
• Block control is used in garment and magazine industries where you need to keep things separate.
• Load control is used where machines have a bottleneck.
• Batch control is very common in the food processing industries. Ingredients that components need to be are scheduled in relation to the final product.
• Project Control is often used for expensive, unique items.

Planning of Machine Requirements

• Capacity in manufacturing is a measurement of the output a system can achieve.
• System capacity depends on inputs and outputs.
• System resources are raw material, labor, machinery, facilities and methods.
• At a known processing time or standard tie, the machine requirements can be met with the appropriate production level.

Algorithms and Software Application

• Manufacturing needs to respond quickly to customers' economical and quickly evolving needs.
• Research and development are perfecting techniques for analyzing complex manufacturing systems and digital tools.
• Many companies can not exist with traditional methods.
• Manuplan and MPX were main exponents around the 1980's for digitizing systems.
• Applications of a mathematical theory of queuing networks can support this style of manufacturing.
• The queues help manage the optimal size of batch produced.
• An optimal sized and small batch is one of the requirements for the implementation of just-in-time manufacturing.
• Queueing network theory aids in complex problems like telecommunications networks.
• Cloud platforms and computing power are evolving digital tools.

Space and Labor Requirements

• Early in a plant project, it is important to know the full scope of space that needs to be occupied.
• A sheet details the requirements of space.
• Design depends on machines, manufacturing stations, shapes and sizes.
• Industrial layout is very important for the amount of space required.
• Labor = (# of Products * Standard time) / Factory efficiency.
• Modern manufacturing companies must mix standard requirements like machinery.
• Analysis and design programs are required for the modern organization.

Computer Aided Process Planning (CAPP)

• The acronym CAPP in English for "computer-aided process planning".
• It's a highly effective technology that is used by manufacturing organizations.
• It is meant to automate planning through the application of digital tool.
• It can be an alternative to traditional processing.
• Process planning involves the functions necessary to produce a part.
• A set of procedures and instructions is used to get a specification.
• Computer systems make this easier.
• The result includes routing sheets, including the required standards, operations, necessary machine and toolings.

High Technical Requirements in Computers aided systems

• There are very high technical requirements to install these systems.
• These often coordinate software packages by with other manufacturing platforms.
• They are extremely useful for scheduling of large processes and planning.
• A problem is to task planners with the best sequence possible.

Aided Planning Systems

• The best system must coordinate with computer-aided production planning system.
• Problems with the current system may be in the processes.
• Without the computer aided plans it is impossible to compete with those who have one.
• CAPP methods can be classified into 2 large groups:
  • variant (derivative) systems
  • generative system
• Most of the type systems are least complicated.
• Generative systems work from the design and knowledge within the manufacturing system,
• The future of this system is machine learning.
• One that can develop from data automatically given the name ACAPP.
• A key task in creating this is developing the right rules for the objects designed.

Process Planning Evolution

• Originally manual scheduling was used to address issues by part classification.
• CAPP systems started as tools to store this in computer memory.
• CAPP systems now use a methodology similar to that of a human manual.
• If the technology is needed for the new point it can be worked to in with some modifications.
• The next advancement was the introduction of generative systems.
• They create a process that doesn't need manual integration.
• Al and Computer Vision systems have been introduced in recent years for design.
• Automatic feature recognition has greatly aided this.
• Some companies are backing this tech to have it commercially made.

CAPP System Criteria

• Only commercially active systems are generative systems that can be commercially active.
• The process for set up is relatively simple when setting up the system and requires relating to the code.
• Key steps include establishing decision rules of items.

Advantages of CAPP Variant

• Hardware cost is lower for hardware and software.
• Installation and development requirements are generally less.
• Currently, variant systems are much more reliable for smaller companies.
• The quality is still not very high because they require an expert.
• generative system can generate without expert, has more complex features.
• The CAPP system depends on the types of complexity used.
• Access to process planning includes:
  • Locating
  • Selecting
  • Organizing
  • Interpreting
  • Synthesizing
• Can be determined by the part drawings.
• This is regardless of the method used.
• Decisions throughout the various steps of setup require the expertise.
• Other steps need to ordered.

Conclusion to Automated Computing Systems

• Automated systems are performed without any human interference.
• Process planning is extremely important for the machinery in the production.
• Planned processes are helpful to ensure that the production is optimal.
• Allows production plans to perform to partial or full capacity digitally.
• Available tools often improve the production capacity.
• Generally systems that require a program are more in demand than a system to implement

Computer Aided Production Planning and Control

• Using computers to ensure that processes offer total benefits of the controls involved.
• This helps increase plant efficiency, quality, operability, etc.
• It improves design, machines individually, and in groups.

Fundamentals of Computer Control

• The best use is the Programmable Logic Controller (PLC) that is used in automation.
• Process elements are part of a manufacturing process.
• Input elements are used by the computer to use the process.
• Output mechanisms are used by the computer to send signals.
• Sytemsoftware carries out the programmed action.
• Processes*
• Communications Actions : used to modify system status
• Communications Action : used for the communications between machinery.
• systems have the following types of programs:
  • sequential: one action comes after the other.
  • Multitasking: actions can be executed simultaneously.
  • Real time: exectuion depends on the state of the system.
• Conditions can be schedules, clocks, and sensors and other methods.
• Computers can also use these technologies.
• Computer control system tasks*
• Data Acquisition
• Sequential control
• Direct digital control
• Human-machine interface

Control Objectives

• Be efficient and facilitate action
• Ensure process safety
• Provide Quality in the product
• Reduce Scraps and shorten cycle times
• Other than sequential there can be feedback, inferential, and adaptive control.
• Computer aided Production Planning and Control (PP&C)*
• Computer programs are interactive with humans to best use the computer for production.
• PP&C are information systems for the platform.
• The programming is capable of coordinating the broadcast around them.

System Elements

• Output interface
• Programming editor for generation and manipulation.
• Database management system
• Evaluation and automatic programming.
• Plan Simulations*
• Systems all have simulations of the plan that is set up.
• All systems have parameters and variables involved in the process.
• It has a wide range of systems.
• The goal is to have a simulation tool to describe the process.

System

• A set of components designed to achieve the same goal
• Model to represent the system
• Objective that you want to achieve
• And the scope
• A tool that has been used for a long time for academic use is ProModel.
• It has a number of tools for various kinds of analysis.
• The software can be used for optimization.

Simulation Software

• Tecnomatix Plan Simulation belongs to the Siemens PLM family that allows systems to
• It allows you to assess things like logistics, machinery, the production costs involved, and integrate other technologies and simulations like Kanban.

Conclusions

• The role of a skilled engineer is to be able to operate a plant skillfully and that they are competent in the systems that are working in the plant.
• The control engineer must assess and understand the system to the best of their abilities
• To determine needs.
• Assess the equipment
• Manage the actions of the systems

Introduction to Group Technology

• The basis location in the production schedule where parts can be assigned.
• It aims to optimally exploit what the parts have in common to improve efficiency, like machines and process to limit part movement.
• Areas like design and manufacturing are areas where the process can be applied.
• It is key to minimize effort that is used to classify coding of the parts.

Group Technology Background

• In order to ensure a production system is adequate for high quantity products, production can be carried out in batches and downtime is required.
• They minimize inventories and are designed to be as efficient as possible.
• Advantages*
• Production methodology for medium volume parts that can take automation using advanced technologies that can enhance a system.

Family Concepts

• The family of parts can be grouped into families of parts which are made of similar operation in manufacturing.
• It is important to know that parts are geometrically identical and what makes them up needs to be considered.
• Machines used to make them may be different.
• Advantages*
• It makes things more standardized.
• Designs can be already be developed.
• It is easier to track history and data of designs.
• Operations costs can be lowered.
• Time of planning is minimized
• Disadvantages*
• coding part families can be considerable and take time.
• costs can be higher for parts.
• machines can be disorganized.
• parts can be relocated.

Analyze advanced strategies for optimizing manufacturing systems. Covers techniques for scheduling, integrating human-centric design, and implementing statistical process control to enhance efficiency, reduce costs, and improve quality in complex manufacturing environments.