Intro to Manufacturing Operation PDF

Manufacturing Operations Manufacturing Technology II (Part 2): 1 Dr Hilmi Hussin Objectives By end of the class, students should be able to : Describe the difference between discrete manufacturing vs....

Manufacturing Operations Manufacturing Technology II (Part 2): 1 Dr Hilmi Hussin Objectives By end of the class, students should be able to : Describe the difference between discrete manufacturing vs. process manufacturing Explain the mathematical model of the relationship between product and production. Perform calculation and analysis of production system based on mathematical model. Perform cost analysis on manufacturing operation 2 Manufacturing Defined - Technological Definition Application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products Manufacturing also includes the joining of multiple parts to make assembled products Accomplished by a combination of machinery, tools, power, and manual labor Almost always carried out as a sequence of operations Manufacturing Defined - Technological Definition Manufacturing Defined - Economic Definition 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 Examples: Converting iron ore to steel adds value Transforming sand into glass adds value Refining petroleum into plastic adds value Manufacturing Defined - Economic Definition  Manufacturing Industries and products Three types of Manufacturing industries: Primary Industries -Cultivate and exploit natural resources Eg: Mining, Petroleum, Agriculture Secondary Industries- Converts output from primary industries to products Eg: Automotive, Computers, Hand phones, consumer appliances Tertiary Industries- Service sectors Eg: Hotels, Legal, Finance/Banking 7 More Industry Classifications Process industries, e.g., chemicals, petroleum, basic metals, foods and beverages, power generation Continuous production Batch production Discrete product (and part) industries, e.g., cars, aircraft, appliances, machinery, and their component parts Continuous production Batch production Process vs. Discrete manufacturing Process manufacturing includes chemical, pharmaceuticals, petroleum Process Continuous Process Batches Batch Discreet Manufacturing includes car, hand phones, computers Process Continuous Process Batches 9 Batch  Classifications of Manufacturing Processes Solidification Processing operations: use energy to processes transforms a work material from one state Particulate of completion to more advanced state Shaping processes closer to final desired part / product processes Deformation processes Material Removal Processes Operations Property enhancing Heat treatment processes Cleaning & Surface treatment Surface processing Coating & deposition processes processes Manufacturing Processes Welding Permanent Brazing & joining soldering processes Assembly Adhesive bonding Operations Threaded Assembly operations: Mechanical fasteners fastening joins two or more components to create a new Permanent entity, ie. Assembly, sub-assembly, joining part fastening methods 10 Manufacturing Video External Disk Drives manufacturing 11 Production System Manufacturing Processes and Assembly Operation Manufacturing System production lines (automation/manual): cells, machine tools, robotic, group technology Material Handling and Storage Moving and storing materials between processing and/or assembly Automation and Control technologies Regulation and control of automated operations/machines/processes Manufacturing Support Systems Manufacturing Engineering: optimize the processes and quality Production planning and control: logistics, ensure enough capacity to meet production schedule Quality Control System Quality control, inspection, to ensure products meet the quality standard and specification 12  Overview of Production System Enterprise level Manufacturing Support Manufacturing System Support system Quality Control System Factory level Production Manufacturing System system Automation and Material Handling Facilities Control Technologies Technologies Engineering Finished Materials Manufacturing Processes and Assembly operations Products 13 Plant layout -Types A. Fixed – Positioned Layout The product remains in the single location during its entire production 14 B. Process Plant Layout Equipment is arranged according to function or type 15 B. Process Plant Layout 16 C. Product-oriented layout Flow line production Multi equipment are arranged in sequence, and the work units are physically through the sequence to complete product. 17 C. Product-oriented layout 18 D. Cellular layout Each cell is designed to produce a limited variety of part configuration 19 D. Cellular layout 20 Production Facilities Relationship between Production quantity (Q) and Product variety (P) Low production: 1 – 100 units Medium: 100 – 10,000 units High: 10,000 – 1 million units 21 Production Facilities Relationship between Plant Layout and type of Production Facility 22  Example of Process Manufacturing The Process of Refining Crude Oil 23 Source: http://www.brighthubengineering.com/marine-engines-machinery/60603-the-process-of-refining-crude-oil/  Processing & Assembly Operation Raw Material handling & storage In process In process Finish Material Material Material Raw Material handling & handling & handling & storage storage storage Wafer Fab Assembly Inspection/Test Ship out Scrap Processing Assembly operation Inspection/Test operation Joining of parts to Checking of products Change of work parts form new entity per specification shape , physical e.g.: Joining of die e.g.: properties & with substrate on Testing H/P appearance motherboards + covers functionality e.g.: Changing of to form H/P Inspecting silicon ingot into wafer visual defect with etched circuitry 24 Production concept and Mathematical Model Served as quantitative measurement of manufacturing performance Based on ‘ideal’ case neglecting real case scenario Scrap rate that might impact plan capacity and lead time Unpredictability of equipment performance Unforeseen demand fluctuation 25 Product / Production Relationships Key parameters to determine the organization of manufacturing operations: Product Quantity: Total out of the plant; Q Product variety :Different types of products manufactured; P Complexity of assembled product ; np=Number of parts E.g. number of components Products Approx no of Components Mechanical Pencil 15 Bicycle 750 Car 20,000 Commercial Plane (Boeing 747-400) >6,000,000 Space shuttle 10,000,000 26 Product / Production Relationships Key parameters to determine the organization of manufacturing operations: Complexity of individual parts; no=Number of operation Eq: Stainless steel washer : no=1 (stamping) V-6 Engine Block : no=50 (casting, Machining) Stainless steel washer Engine Block 27 Product / Production Relationships Mathematical Model: Q= Product Qty; Q j=Total qty of style j Qf=Total qty for all styles P=Total number of product variety/style noj=Number of operations in product j nof=Total number of operations in the factory npj=Number of parts in product j npf=Total number of parts in the factory P Qf = Q1 + Q 2 + Q3 +...Qp =  Qj Where j=1,2,3…P j =1 P npf = Q n j =1 j pj Where j =1,2,3…P ; npf = Total parts made in the factory npj = Number of parts in product j 28 Product / Production Relationships If the assumption is that the number of product design P are produced in equal quantities Q, all products have the same number of components np and all components go through same number of operation no ,then Qf =PQ npf = PQnp nof =PQnpno nof is the total number of operations 29 Product/Production Relationships One H/P company is planning a new product line and therefore a new plant needs to be built. The new H/P will have 20 different product variety and the annual production is expected to be 10000 units/product. Each product has 40 different components and all processing will be done in the plant. Total processing time per component is 1.0 min and each component will go through 5 different process steps. One worker will work 2000 hrs in a year. Find out:- A) Total production operation B) Number of worker required P= 20; Q= 10000; np=40; no=5; Time per operation=1 min nof =PQnpno=20 x 10000 x 40 x 5 =40,000,0000 operations Total number of hrs/year = (1min/operation x 40,000,000 operations/year x 1 hr/60 min) = 666,666 hrs/year 666,666hrs / year Therefore # of workers: 2000hrs / wor ker = 333 workers 30 Example Problem The ABC Company is planning a new product line and will build a new plant to manufacture the parts for a new product line. The product line will include 50 different models. Annual production of each model is expected to be 1000 units. Each product will be assembled of 400 components. All processing of parts will be accomplished in one factory. There are an average of 6 processing steps required to produce each component, and each processing step takes 1.0 minute (includes an allowance for setup time and part handling). All processing operations are performed at workstations, each of which includes a production machine and a human worker. If each workstation requires a floor space of 250 ft2, and the factory operates one shift (2000 hr/yr), determine (a) how many production operations, (b) how much floorspace, and (c) how many workers will be required in the plant 31  Example Problem The ABC Company is planning a new product line and will build a new plant to manufacture the parts for a new product line. The product line will include 50 different models. Annual production of each model is expected to be 1000 units. Each product will be assembled of 400 components. All processing of parts will be accomplished in one factory. There are an average of 6 processing steps required to produce each component, and each processing step takes 1.0 minute (includes an allowance for setup time and part handling). All processing operations are performed at workstations, each of which includes a production machine and a human worker. If each workstation requires a floor space of 250 ft2, and the factory operates one shift (2000 hr/yr), determine (a) how many production operations, (b) how much floorspace, and (c) how many workers will be required in the plant (a) nof = PQnpno = 50(1000)(400)(6) = 120,000,000 operations in the factory per year. (c) Total operation time = (120 x 106 ops)(1min./(60 min./hr)) = 2,000,000 hr/yr. At 2000 hours/yr per worker, w = = 1000 workers. (b) Number of workstations n = w = 1000. Total floorspace = (1000 stations)(250 ft2/station) = 250,000 ft2 32 In-Class Exercise A plant produces three product lines: A, B and C. There are six models within product line A, four models within B and eight within C. Average annual production quantities of each A model is 500 units, 700 units for each B model and 1100 units for each C model. Determine the values of 𝑃 and 𝑄𝑓 for this plant. 33