Manufacturing Systems - University of the Philippines Diliman PDF

University of the Philippines Diliman Department of Mechanical Engineering Manufacturing Systems CHALLENGES IN MANUFACTURING SYSTEMS INDUSTRY – RELATED https://www.thewakefieldcorp.com/project/lifetime-products-manufacturing-faci...

University of the Philippines Diliman Department of Mechanical Engineering Manufacturing Systems CHALLENGES IN MANUFACTURING SYSTEMS INDUSTRY – RELATED https://www.thewakefieldcorp.com/project/lifetime-products-manufacturing-facility/ University of the Philippines Diliman – Department of Mechanical Engineering 3 CHALLENGES IN MANUFACTURING SYSTEMS INHERENT TO SYSTEMS University of the Philippines Diliman – Department of Mechanical Engineering 4 Challenges in manufacturing systems Machines Operator Post-operated part Workpieces This Photo by Unknown Author is licensed under CC BY-SA This Photo by Unknown Author is licensed under CC BY Operation Consumables This Photo by Unknown Author is licensed under CC BY Waste University of the Philippines Diliman – Department of Mechanical Engineering 6 Challenges in manufacturing systems Machines Operator Blocked Post-operated Starved part Workpieces This Photo by Unknown Author is licensed under CC BY-SA This Photo by Unknown Author is licensed under CC BY Operation Consumables This Photo by Unknown Author is licensed under CC BY Waste University of the Philippines Diliman – Department of Mechanical Engineering 7  Rule #1: Nothing happens until everything is present and ready Rule #2: whatever does not arrive last must wait. University of the Philippines Diliman – Department of Mechanical Engineering 8  WAITING Minimize waiting time GOAL: Optimized profit University of the Philippines Diliman – Department of Mechanical Engineering 9  WAITING Under- utilization Idle work- Inventory force University of the Philippines Diliman – Department of Mechanical Engineering 10  MANUFACTURING SYSTEM TYPES University of the Philippines Diliman – Department of Mechanical Engineering 11 MANUFACTURING SYSTEM TYPES 1. Job shop 2. Flow shop 3. Transfer lines 4. Flexible manufacturing systems (FMS) 5. Cellular manufacturing (TPS) University of the Philippines Diliman – Department of Mechanical Engineering 12  JOB SHOP Wide variety of skills High skilled worker requires Usually produces small batches of products or custom products University of the Philippines Diliman – Department of Mechanical Engineering 13 University of the Philippines Diliman – Department of Mechanical Engineering FLOW SHOP Follows a fixed linear structure Fixed set of inputs and outputs. Grouped by process order of product Low flexibility Low variety High volume High production fraction Applications: pencil manufacturing, steelmaking, automobile assembly, etc. University of the Philippines Diliman – Department of Mechanical Engineering 16 FLOW SHOP LAYOUT University of the Philippines Diliman – Department of Mechanical Engineering 17 TRANSFER LINES Synchronous production line with several machines and workstations integrated into one system. Usually connected by conveyor systems. Operate like a single machine producing one unit per cycle. Automated material handling Very high production rates Reduced labor cost Reduce work-in-process Reduced transportation distance and time. University of the Philippines Diliman – Department of Mechanical Engineering 18 TRANSFER LINES University of the Philippines Diliman – Department of Mechanical Engineering 19 TRANSFER LINES https://www.youtube.com/watch?v=DSU8JH2kqHc - University of the Philippines Diliman – Department of Mechanical Engineering 20 TRANSFER LINE University of the Philippines Diliman – Department of Mechanical Engineering 21  FLEXIBLE MANUFACTURING SYSTEMS (FMS) Allows adaptability when faced with production changes Consist of several machine tools, parts and tool handling devices Flexibility: management similar to job shop University of the Philippines Diliman – Department of Mechanical Engineering FLEXIBLE MANUFACTURING SYSTEMS University of the Philippines Diliman – Department of Mechanical Engineering 23 CELLULAR MANUFACTURING SYSTEMS University of the Philippines Diliman – Department of Mechanical Engineering 25 Summary University of the Philippines Diliman – Department of Mechanical Engineering 26  LITTLE’S LAW University of the Philippines Diliman – Department of Mechanical Engineering 27 LITTLE’S LAW Average generic Average arrival rate “customers” Average time Steady State (mean arrival rate is constant) University of the Philippines Diliman – Department of Mechanical Engineering 28  LITTLE’S LAW EXAMPLE WILLOW RUN FACTORY (OVER A MILE OR 5280 FT) B-24: 68 FT IN LENGTH 453 AIRPLANES IN 468 HRS University of the Philippines Diliman – Department of Mechanical Engineering 29 LITTLE’S LAW EXAMPLE: what is the average tie to complete a plane? University of the Philippines Diliman – Department of Mechanical Engineering 30 2 REASONS WHY LITTLE’S LAW IS USEFUL 1. System is steady state or stationery 2. Can apply subsystems Industry applications: Autonomous robots assemble an X model SUV at the BMW manufacturing https://www.food-safety.com/articles/6805-recent-advances-in-food- facility in Greer, South Carolina, U.S. November 4, 2019. REUTERS/Charles processing Mostoller University of the Philippines Diliman – Department of Mechanical Engineering 31  UNRELIABLE MACHINE University of the Philippines Diliman – Department of Mechanical Engineering 32 UNRELIABLE MACHINE University of the Philippines Diliman – Department of Mechanical Engineering 33 UNRELIABLE MACHINE University of the Philippines Diliman – Department of Mechanical Engineering 34 UNRELIABLE MACHINE University of the Philippines Diliman – Department of Mechanical Engineering 35 UNRELIABLE MACHINE University of the Philippines Diliman – Department of Mechanical Engineering 36 UNRELIABLE MACHINE University of the Philippines Diliman – Department of Mechanical Engineering 37  MACHINE LINE Deterministic Systems University of the Philippines Diliman – Department of Mechanical Engineering 38 1 MACHINE LINE University of the Philippines Diliman – Department of Mechanical Engineering 39  1 MACHINE LINE D/D/1 Queue University of the Philippines Diliman – Department of Mechanical Pitch deck 40 Engineeringtitle  MACHINE LINE Stochastic Systems University of the Philippines Diliman – Department of Mechanical Engineering 41 1 MACHINE LINE University of the Philippines Diliman – Department of Mechanical Engineering 42 1 MACHINE LINE M/M/1 Queue University of the Philippines Diliman – Department of Mechanical Engineering 43  MULTIPLE MACHINES AND INVENTORY University of the Philippines Diliman – Department of Mechanical Engineering 44 ZERO BUFFER LINE Assumptions: Operation time: tau 1. failure: operation dependent 2. Time down