IE 469 Manufacturing Systems PDF

IE 469 Manufacturing Systems Introduction Ateekh-Ur-Rehman IE 469  Outlines 1. Production Systems 2. Automation in Production Systems 3. Manual Labor in Production Systems 4. Automation Principles and Strategies Ateekh-Ur-Rehman IE 469 ...

IE 469 Manufacturing Systems Introduction Ateekh-Ur-Rehman IE 469  Outlines 1. Production Systems 2. Automation in Production Systems 3. Manual Labor in Production Systems 4. Automation Principles and Strategies Ateekh-Ur-Rehman IE 469  Production System Defined  A collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company. Two categories:  Facilities – the factory and equipment in the facility and the way the facility is organized (plant layout).  Manufacturing support systems – the procedures used by a company to manage production and to solve technical and logistics problems in ordering materials, moving work through the factory, and ensuring that products meet quality standards Ateekh-Ur-Rehman IE 469 The Production System Ateekh-Ur-Rehman IE 469  Production System Facilities  Facilities include the factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations.  Plant layout – the way the equipment is physically arranged in the factory  Manufacturing systems – logical groupings of equipment and workers in the factory  Production line  Stand-alone workstation and worker Ateekh-Ur-Rehman IE 469  Manufacturing Systems  Three categories in terms of the human participation in the processes performed by the manufacturing system: 1. Manual work system - a worker performing one or more tasks without the aid of powered tools, but sometimes using hand tools 2. Worker-machine system - a worker operating powered equipment 3. Automated system - a process performed by a machine without direct participation of a human Ateekh-Ur-Rehman IE 469  Categories of Manufacturing Systems (a) Manual work system, (b) worker-machine system, and (c) fully automated system Ateekh-Ur-Rehman IE 469  Manufacturing Support Systems  Manufacturing support involves a sequence of activities that consists of four functions: 1. Business functions - sales and marketing, order entry, cost accounting, customer billing. 2. Product design - research and development, design engineering, prototype shop. 3. Manufacturing planning - process planning, production planning, MRP, capacity planning. 4. Manufacturing control - shop floor control, inventory control, quality control. Ateekh-Ur-Rehman IE 469 Sequence of Information-Processing Activities in a Manufacturing Firm Ateekh-Ur-Rehman IE 469  Automation in Production Systems  Two categories of automation in the production system: 1. Automation of manufacturing systems in the factory. 2. Computerization of the manufacturing support systems.  The two categories overlap because manufacturing support systems are connected to the factory manufacturing systems.  Computer-Integrated Manufacturing (CIM) Ateekh-Ur-Rehman IE 469 Computer Integrated Manufacturing Ateekh-Ur-Rehman IE 469  Automated Manufacturing Systems Examples:  Automated machine tools  Transfer lines  Automated assembly systems  Industrial robots that perform processing or assembly operations  Automated material handling and storage systems to integrate manufacturing operations  Automatic inspection systems for quality control Ateekh-Ur-Rehman IE 469  Automated Manufacturing Systems Three basic types: 1. Fixed automation 2. Programmable automation 3. Flexible automation Ateekh-Ur-Rehman IE 469  Fixed Automation  A manufacturing system in which the sequence of processing (or assembly) operations is fixed by the equipment configuration.  Typical features:  Suited to high production quantities  High initial investment for custom-engineered equipment  High production rates  Relatively inflexible in accommodating product variety Ateekh-Ur-Rehman IE 469  Programmable Automation  A manufacturing system designed with the capability to change the sequence of operations to accommodate different product configurations. Typical features:  High investment in general purpose equipment  Lower production rates than fixed automation  Flexibility to deal with variations and changes in product configuration  Most suitable for batch production  Physical setup and part program must be changed between jobs (batches) Ateekh-Ur-Rehman IE 469  Flexible Automation  An extension of programmable automation in which the system is capable of changing over from one job to the next with no lost time between jobs. Typical features:  High investment for custom-engineered system  Continuous production of variable mixes of products  Medium production rates  Flexibility to deal with soft product variety Ateekh-Ur-Rehman IE 469 Product Variety and Production Quantity for Three Automation Types Ateekh-Ur-Rehman IE 469  Computerized Manufacturing Support Systems  Objectives of automating the manufacturing support systems:  To reduce the manual and clerical effort in product design, manufacturing planning and control, and the business functions  Integrates computer-aided design (CAD) and computer- aided manufacturing (CAM) in CAD/CAM  CIM includes CAD/CAM and the business functions of the firm Ateekh-Ur-Rehman IE 469  Reasons for Automating 1. Increase labor productivity 2. Reduce labor cost 3. Mitigate the effects of labor shortages 4. Reduce or remove routine manual and clerical tasks 5. Improve worker safety 6. Improve product quality 7. Reduce manufacturing lead time 8. Accomplish what cannot be done manually 9. Avoid the high cost of not automating Ateekh-Ur-Rehman IE 469  Manual Labor in Production Systems  Is there a place for manual labor in the modern production system?  Answer: YES  Two aspects: 1. Manual labor in factory operations 2. Labor in manufacturing support systems Ateekh-Ur-Rehman IE 469  Manual Labor in Factory Operations  The long term trend is toward greater use of automated systems to substitute for manual labor.  When is manual labor justified?  Some countries have very low labor rates and automation cannot be justified  Task is technologically too difficult to automate  Short product life cycle  Customized product requires human flexibility  To cope with ups and downs in demand  To reduce risk of new product failure Ateekh-Ur-Rehman IE 469  Labor in Manufacturing Support Systems  Product designers who bring creativity to the design task  Manufacturing engineers who  Design the production equipment and tooling  And plan the production methods and routings  Equipment maintenance  Programming and computer operation  Engineering project work  Plant management Ateekh-Ur-Rehman IE 469  Automation Principles and Strategies 1. The USA Principle 2. Ten Strategies for Automation and Process Improvement 3. Automation Migration Strategy Ateekh-Ur-Rehman IE 469  U.S.A Principle 1. Understand the existing process  Input/output analysis  Value chain analysis  Charting techniques and mathematical modeling 2. Simplify the process  Reduce unnecessary steps and moves 3. Automate the process  Ten strategies for automation and production systems  Automation migration strategy Ateekh-Ur-Rehman IE 469  Ten Strategies for Automation and Process Improvement 1. Specialization of operations (special purpose m/c) 2. Combined operations (Sequence of operations) 3. Simultaneous operations (Combined operations at one workstation) 4. Integration of operations (Several workstations linked by automated work handling devices) 5. Increased flexibility (max utilization of m/c for job shop) 6. Improved material handling and storage (reduce nonproductive time) 7. On-line inspection (Reduce scraps) 8. Process control and optimization (Reduce the individual process times) 9. Plant operations control (Using Computer Networking within the factory) 10. Computer-integrated manufacturing (CIM) Ateekh-Ur-Rehman IE 469  Automation Migration Strategy For Introduction of New Products 1. Phase 1 – Manual production  Single-station manned cells working independently  Advantages: quick to set up, low-cost tooling 2. Phase 2 – Automated production  Single-station automated cells operating independently  As demand grows and automation can be justified 3. Phase 3 – Automated integrated production  Multi-station system with serial operations and automated transfer of work units between stations Ateekh-Ur-Rehman IE 469 Automation Migration Strategy Ateekh-Ur-Rehman IE 469 Technological Categories of the Production System Ateekh-Ur-Rehman IE 469 Questions? Ateekh-Ur-Rehman IE 469