Lecture 4, Fundamentals of Manufacturing Systems PDF

Lecture 4 Fundamentals of Manufacturing Systems  Manufacturing Systems Aspects Four Aspects of Manufacturing Systems Based on such concepts and views of the meanings of manufacturing and systems so far discussed, ‘manufacturing (or production) systems’ are now further defined through the f...

Lecture 4 Fundamentals of Manufacturing Systems  Manufacturing Systems Aspects Four Aspects of Manufacturing Systems Based on such concepts and views of the meanings of manufacturing and systems so far discussed, ‘manufacturing (or production) systems’ are now further defined through the following main aspects: Physical Systems. Operations. Information Systems. People.  Manufacturing Systems Aspects Physical Systems: Facilities: This includes the buildings, warehouses, and other physical structures that house the manufacturing operation. Equipment: This includes the machinery, tools, and other physical assets used to transform raw materials into finished products. Material handling systems: This includes the equipment and processes used to move materials around the manufacturing facility, such as conveyor belts, robots, and forklifts.  Manufacturing Systems Aspects Operations: Production planning and scheduling: This involves deciding what products to make, in what quantities, and when. It also involves scheduling the use of equipment and labor to meet production deadlines. Process design: This involves designing the sequence of steps required to transform raw materials into finished products. Inventory management: This involves ordering, storing, and using materials and supplies efficiently. Quality control: This involves ensuring that products meet the required standards. Maintenance: This involves keeping equipment and machinery in good working order.  Manufacturing Systems Aspects Information Systems: Manufacturing execution systems (MES): These systems collect and track data from the manufacturing process, such as production rates, machine downtime, and inventory levels. Enterprise resource planning (ERP) systems: These systems integrate information from all aspects of a business, including manufacturing, finance, and sales. Computer-aided design (CAD) and computer-aided manufacturing (CAM): These technologies are used to design products and create the instructions for manufacturing them. People: Workers: The people who operate the equipment and perform the tasks necessary to produce goods. Managers: The people who oversee the manufacturing process and make decisions about how to improve it. Engineers: The people who design and develop new products and manufacturing processes. Manufacturing Systems Structure Manufacturing Systems Transformation  Integrated Manufacturing Systems Integrated manufacturing systems, also known as Computer-Integrated Manufacturing (CIM), refer to a manufacturing approach that utilizes computer-controlled machinery and automation to create a seamless and interconnected production environment. Four Major Functions in an Integrated Manufacturing System (1) The production function converts production resources (especially raw materials) into products. (2) The design function plans and draws the products/parts. (3) The management function plans and controls design and production activities. (4) The strategic planning function consists of decision-making on strategic issues. Integrated Manufacturing Systems  Integrated Manufacturing Systems Calculations Example: An integrated manufacturing system produces springs for car suspension. The system operates for a total of 8 hours per day (480 minutes). Production rate: The system can produce 5 springs per minute when operational. Planned downtime: The system requires 30 minutes for scheduled maintenance and breaks per day. Unexpected downtime: the system is expected to have a margin of 15 minutes for any unexpected downtime. What is the utilization rate of the integrated manufacturing system?  Integrated Manufacturing Systems Calculations Solution: Calculate total available production time: Total available time = Total operating time - Planned downtime = 480 minutes - 30 minutes = 450 minutes Calculate actual production time: Actual production time = Total available time - Unexpected downtime = 450 minutes - 15 minutes = 435 minutes Calculate the total number of springs produced: Total springs produced = Production rate * Actual production time = 5 spring/minute * 435 minutes = 2175 springs Calculate the utilization rate: Utilization rate = (Actual production time / Total available time) * 100% = (435 minutes / 450 minutes) * 100% = 96.67% Therefore, the utilization rate of the integrated manufacturing system is 96.67%.  Integrated Manufacturing Systems Calculations Example: An integrated manufacturing system requires designing a process flow for assembling a new product with three components: A, B, and C. Component A: Requires processing time of 3 minutes per unit. Component B: Requires processing time of 2 minutes per unit. Component C: Requires processing time of 1 minute per unit. Two alternative process flow designs are proposed: Option 1: Sequential processing - Assemble A first, then B, and finally C. Option 2: Parallel processing - Assemble A and B simultaneously, then add C at the end. Assuming a daily demand of 100 assembled products, calculate the daily production time for each option and determine the most efficient option.  Integrated Manufacturing Systems Calculations Solution: Option 1: Sequential Processing Total processing time per unit: Processing time = Processing time of A + Processing time of B + Processing time of C = 3 minutes + 2 minutes + 1 minute = 6 minutes Daily production time: Daily production time = Total processing time per unit * Daily demand = 6 minutes/unit * 100 units/day = 600 minutes/day Option 2: Parallel Processing Combined processing time of A and B: Combined processing time = Max(Processing time of A, Processing time of B) = Max(3 minutes, 2 minutes) = 3 minutes Total processing time per unit: Processing time = Combined processing time + Processing time of C = 3 minutes + 1 minute = 4 minutes Daily production time: Daily production time = Total processing time per unit * Daily demand = 4 minutes/unit * 100 units/day = 400 minutes/day