Introduction To Industrial Systems PDF

Introduction To Industrial Systems Industrial systems refer to the combination of technologies, machinery, processes, and human resources used to produce goods and services in a factory or industrial setting. These systems are designed to efficiently manage and control the production process, from r...

Introduction To Industrial Systems Industrial systems refer to the combination of technologies, machinery, processes, and human resources used to produce goods and services in a factory or industrial setting. These systems are designed to efficiently manage and control the production process, from raw materials to finished products. The goal is to ensure that production is efficient, safe, and of high quality, while minimizing waste and reducing costs. Components of Industrial Systems 1. Machinery and Equipment - These are the physical tools and machines used in the production process, such as conveyors, robotic arms, CNC machines, and assembly lines. They perform tasks like cutting, shaping, assembling, and packaging products. 2. Control Systems - Control systems manage and monitor the operation of machinery and processes. They can include computer programs (e.g., PLCs, SCADA systems) that control the timing, speed, and sequence of operations. This ensures consistency and precision in production. 3. Automation and Robotics - Automation involves using technology to perform tasks that would otherwise require human intervention. Robotics is a key part of this, with robots being used for repetitive, dangerous, or precision tasks. Automation increases efficiency and reduces the potential for human error. 4. Human Resources: - Skilled workers, engineers, and technicians who design, operate, maintain, and improve the industrial system. Human oversight is essential for troubleshooting, making decisions, and optimizing the system. 5. Materials Handling Systems - These systems involve the movement, storage, and control of materials throughout the production process. Examples include conveyor belts, forklifts, and automated storage and retrieval systems. 6. Information and Data Management - The collection, processing, and analysis of data related to production processes, equipment performance, and product quality. This includes using software for inventory management, production scheduling, and quality control. 7. Energy and Power Systems - These provide the necessary energy to run machinery and equipment. Power systems can include electricity, hydraulics, pneumatics, and even renewable energy sources. Efficient energy management is crucial for reducing operational costs. 8. Safety and Environmental Control - Systems that ensure safe operation and compliance with environmental regulations. This includes safety protocols, emergency shutoff systems, and pollution control measures to protect workers and the environment. 9. Quality Control Systems - These systems are designed to monitor and ensure the quality of the products being produced. They include inspections, testing, and the use of sensors to detect defects or deviations from standards. 10. Supply Chain and Logistics - The management of the flow of raw materials into the system and the distribution of finished products to customers. This includes inventory management, procurement, and transportation logistics. Overview Of Manufacturing Processes Manufacturing Definition, Types, Examples Manufacturing ★A system in which raw materials are transformed into finished products while adding value in the process The creation of finished goods through the use of tools, human labor, machinery, and chemical processing. Manufacturing allows businesses to sell finished products at a higher cost than the value of the raw materials used. Large-scale manufacturing allows for goods to be mass-produced using assembly line processes and advanced technologies as core assets. Efficient manufacturing techniques enable manufacturers to take advantage of economies of scale, producing more units at a lower cost. Hand manufacturing involves the use of basic tools through more traditional processes. This form of manufacturing is often associated with decorative art, textile production, leatherwork, carpentry, and some metalwork. Handmade goods are labor-intensive and require a lot of time. In some cases, they can command a high price, depending on the supplier and the type of goods. For instance, one-of-a-kind handmade fashion items can be sold at a higher price compared to something mass-produced. Types of Manufacturing 1. Additive Manufacturing This type of manufacturing is commonly referred to as 3D printing. It involves the use of layers that are built up upon each other to create shapes and patterns in a three-dimensional process using a special piece of equipment, such as a 3D printer. 2. Advanced Manufacturing This method involves new forms of technology to improve the production process. Companies can add even more value to the raw materials they use to better serve their target markets. Newer technologies also help bring new products to market faster while increasing output. 3. Contract Manufacturing This is common in the manufacturing industry. Companies will enter into partnerships and business relationships with other firms to outsource certain manufacturing processes. For example, an automotive company may hire a third party to make parts that it will use in its assembly lines to make cars. Steps of Manufacturing These seven steps, following in sequential order, encompass not only the physical manufacturing of a good but also the stages before and after it is made. Step 1: Develop the Idea Before any tangible good is made, manufacturing begins with concept development and the growth of the product vision. This product vision defines the product, who the target audience is, what the need for the good is, and what competitors exist. Many of these types of questions may define the good and help refine what characteristics will go into the actual product. Step 2: Perform Market Research Though many believe manufacturing only entails the physical aspect of making a good, the manufacturing process still incorporates researching the potential product to explore ways to make it better. This includes understanding what raw materials can be used, what equipment is needed, what conditions the good must be made under, and how the good will differentiate from competing goods. Step 3: Design the Product With research considerations in hand, it's time to design the product. This should always be done in consideration of what the customer will need and use. This also should incorporate any manufacturing limitations discovered during the research stage. This also includes understanding the costs that will go into this product design so you can forecast your product profitability. During this stage, the manufacturing process is most deeply rooted in research and development. Step 4: Finalize and Prototype With the design stage now complete, it's time to make final decisions on the product. This includes choosing what raw materials to use or how to define the manufacturing process. These decisions are implemented by creating an initial prototype. This means drafting a smaller-scale test product that mirrors what the true manufacturing product will be. Step 5: Prototype Testing Once the prototype is complete, it's time to test it. This includes analyzing actual resources that went into the good to better understand how much the actual product will cost and its profit margin. This also includes finding weaknesses or inefficiencies in the manufacturing process. This is often the final stage before mass production begins. However, changes can be made in the future, and this is the time for significant changes without major implications on the product or manufacturing process. Step 6: Manufacture the Good Enough time, testing, and research has been done; it's now time to make the good. The company acquires the machinery and equipment necessary to make full-scale processes to manufacture the goods. The company also invests in the full amount of labor, storage, insurance, and other capacity costs related to a full manufacturing line. Companies may choose to continually improve their processes; instead of returning back to prototype stages, they often review and implement smaller changes during the actual manufacturing step. Step 7: Monitor the Process In order to continually improve, the company must constantly evaluate how the process is going and whether expectations are being met. It must analyze how much the goods cost to make and compare this against sales prices. The company must also evaluate product demand and scale up (or down) based on consumer preference. Manufacturing vs. Production Though sometimes referred to as the same thing, there are subtle differences between manufacturing and production processes. In manufacturing, a company must often solicit raw materials from third-party or external vendors to be processed into finished goods. For production, the company often has ownership of those raw materials. The definition of each encompasses different processes. Production is broader and encompasses manufacturing, as production is simply taking input and yielding an output. Manufacturing, a more specific type of production, is taking a raw material and transforming it into a tangible finished good. MANUFACTURING Often requires procurement of a raw material Output is physical, tangible goods Machinery and labor are essential to the process Is a more specific type of process PRODUCTION Often entails previous ownership of the inputs for the process Output may be tangible or intangible goods Machinery may or may not be required Is a less specific type of process Example of Manufacturing Known for its efficient manufacturing process, Toyota Motor Corporation is a historically well-known and successful manufacturer. The company uses a lean manufacturing system to produce customer vehicle orders in the quickest and most efficient way possible. The company's manufacturing process is based on two core concepts: 1. Jidoka: When there is a production issue, the equipment stops immediately to prevent future defective products. 2. Just-in-Time: Each process manufactures only what is essential for the current process. This includes sourcing just enough material without carrying excessive amounts of reserves. Under jidoka, engineers design and build systems by hand to intricately understand the manufacturing process. Then, they carefully simplify operations and transition to leveraging machines. The goal is for the manufacturing process to leverage repetitive processes that make the manufacturing process more simple and less expensive. Under just-in-time, Toyota strives to eliminate "waste, inconsistencies, and unreasonable requirements on the production line." When an order is received, the production instructions must go to the manufacturing line immediately. The manufacturing line must have the required materials and parts available. Any deficiencies are quickly resolved by swapping similar parts.