General Introduction to Production Engineering PDF

0906506 Lean and Agile Production Systems Prepared by Prof. Dr. Mohammad D. Al-Tahat October 9, 2024 Chapter One General Introduction to Production Engineering 1.1. What is Production? The terms; Mass production, continuous production or flow production...

0906506 Lean and Agile Production Systems Prepared by Prof. Dr. Mohammad D. Al-Tahat October 9, 2024 Chapter One General Introduction to Production Engineering 1.1. What is Production? The terms; Mass production, continuous production or flow production are used interchangeably, the term can be defined as the production of large quantities of standardized products. Together with job production and batch production, mass production is one of the main production methods. Mass production is applied to various kinds of products, such as food, fuel, chemicals, mined minerals, fasteners, and household appliances and automobiles. The words manufacturing and production are often used interchangeably, on view (Groover) is that production has a broader meaning than manufacturing. We say "crude oil production" not "crude oil manufacturing". When used in context of products such as metal parts or automobiles, either word is acceptable. Production systems consist of people, equipment, and procedures designed for the combination of materials and processes that constitute a firm's manufacturing operations. 1.2. What is manufacturing Manufacturing can be defined two ways, one technologic, the other economic. Technologically: manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products. Page 1 of 7 0906506 Lean and Agile Production Systems Prepared by Prof. Dr. Mohammad D. Al-Tahat October 9, 2024 Economically: manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations, manufacturing adds value to the material by changing its shape or properties or by combining it with other materials that have been similarly altered. 2. Production quantity and Product Variety Annual production quantities of particular product type can be classified into three ranges (Groover) (1) low production quantities in the range 1 to 100 units per year (2) medium production, from 100 – 10,000 (3) high production, more than 10,000 units per year Product variety refers to different product designs or types that are produced by the plant, the number of different types made each year can be counted. When the number of products made in the factory is high, this indicates high product variety. We might use the terms soft product variety and hard product variety to describe the differences between products. 3. What is Production System? Production systems consist of people, equipment, and procedures designed for the combination of materials and processes that constitute a firm's manufacturing operations. Page 2 of 7 0906506 Lean and Agile Production Systems Prepared by Prof. Dr. Mohammad D. Al-Tahat October 9, 2024 Production systems can be divided into two categories: (1) Production facilities refer to the physical equipment (production material handling etc.) and the arrangement of equipment (plant layout) in the factory (blue collar worker). The facilities "touch" the product. The equipment is usually organized into logical grouping called manufacturing systems, such as an automated production line, or a machine cell consisting of am industrial robot and two machine tools. Different facilities are required for each of the three quantity ranges: - Low quantity production (1 -100 units/year): The term job shop is often used to describe the production facility. A job shop makes low quantities of complex, specialized, and customized products, such as space capsules, prototype aircraft, and special machinery. The equipment in a job shop is general purpose and the labor force is highly skilled. The job shop must be designed for maximum flexibility in order to deal with the wide product variation (hard product variety). Workers and equipments are brought to the product, rather than moving the product to the equipment. This type of layout is referred to fixed position layout. The individual components of these large products are often made in factories in which the equipment is arranged according to function or type. This arrangement is called a process layout, lathes are in one department, and milling machines are in another and so on. Page 3 of 7 0906506 Lean and Agile Production Systems Prepared by Prof. Dr. Mohammad D. Al-Tahat October 9, 2024 - Medium quantity production (100 – 10,000 units/year) We distinguished two different types of facility, depending on product variety. When product variety is hard the usual approach is batch production, in which a batch of one product is made, after which the manufacturing system is changed over to produce a batch of the next product type, and so on. Change tooling and setup the machinery lost production time; this is a disadvantage of batch production. When product variety is soft, extensive changeovers may not be necessary. It is often possible to configure the production system so that groups of similar products can be made on the same equipment without significant lost time due to setup. The processing is accomplished in cells consisting of several workstations or machines. The term cellular manufacturing is often associated with this type of production. Each cell is designed to produce a limited variety of part configurations, that is, the cell specializes in the production of a given set of similar parts, according to the principles of group technology. The layout is called cellular layout or (9 group technology layout) - High quantity production (More than 10,000 units /year) Refers to mass production, high demand rate for the product, production of single item, two categories of mass production can be distinguished: Page 4 of 7 0906506 Lean and Agile Production Systems Prepared by Prof. Dr. Mohammad D. Al-Tahat October 9, 2024 1. Quantity production. Involves the mass production of single item on single pieces of standard machines, such as stamping presses equipped with special tooling. Typical layouts are process layout and cellular layout. 2. Flow line production. Involves multiple pieces of equipment or workstations arranged in sequence, and the work units are typically moved through the sequence to complete the product. The layout is called a product layout and the workstations are arranged into one long line. Examples include assembly lines of cars, and household appliances, there is no variation in the products made on the line, every product is identical, and the line referred to a single model production line. The term mixed model production line applies to these situations where there is soft variety in the products made on the line, modern automobiles assembly is an example. Cars coming off the assembly line have variations in options. (2) Manufacturing support systems are the procedures used by the company to manage production and solve the technical and logistics problems encountered in ordering materials, moving work through the factory, and ensuring that products meet quality standards (white collar workers). Most of these systems do not directly contact the product, but they plan and control its progress thought the factory. Manufacturing support functions are often carried out by people organized into department such as the following: - Manufacturing engineering, process planning and designing and ordering machine tools - Production planning and control, ordering materials and purchasing, scheduling production, material requirement planning MRP, Resources planning, MRP-II, capacity planning, etc. - Quality control. designing and building products that conform to specifications and satisfy customer expectations Page 5 of 7 0906506 Lean and Agile Production Systems Prepared by Prof. Dr. Mohammad D. Al-Tahat October 9, 2024 4. Type of Production Most manufacturing processes fit into one of five general categories: Repetitive, Discrete, Job Shop, Process (continuous), and Process (batch). The discussion of the types of production facilities is summarized in the figures below, which adds detail to the previous sections by identifying the three types of production facilities and plant layouts used. Some overlap exists among the different facility types. The figure shows, relationship between production type, production quantity, and plant layout Page 6 of 7 0906506 Lean and Agile Production Systems Prepared by Prof. Dr. Mohammad D. Al-Tahat October 9, 2024 I recommend watching the video in the link https://youtu.be/jkkZGHfEYBY which explains these production types. I recommend watching the video in the link https://youtu.be/YR5jjIeIoTg which explains plant layout.. Production Methods, BBC GCSE Bitesize, retrieved 2012-10-26. Page 7 of 7