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1.Fundamentals of Manufacturing Systems
2.Production & Manufacturing
Production is the transformation process of materials of nature into articles of use to mankind using machine, tool and labor on a large scale.
If other supporting activities such as quality control, scheduling production planning, etc. are considered along with production process, its known as Manufacturing.
Production is the transformation process of materials of nature into articles of use to mankind using machine, tool and labor on a large scale.
If other supporting activities such as quality control, scheduling production planning, etc. are considered along with production process, its known as Manufacturing.
3.Manufacturing System
The manufacturing system of an organization is that part whereby resources, flowing within a defined system, are combined and transformed in a controlled manner to add value in accordance with the policies communicated by management.
The manufacturing system has the following characteristics:
1. Manufacturing is an organized activity, so every manufacturing system has an objective.
The manufacturing system of an organization is that part whereby resources, flowing within a defined system, are combined and transformed in a controlled manner to add value in accordance with the policies communicated by management.
The manufacturing system has the following characteristics:
1. Manufacturing is an organized activity, so every manufacturing system has an objective.
2. The system transforms the various inputs to useful outputs.
3. It does not operate in isolation from the other organization system.
4. There exists a feedback about the activities, which is essential to control and improve system performance.
4.Components of a Manufacturing System
A manufacturing system consists of several
components:
Production machines plus tools, fixtures & other related hardware,
Material handling system,
Computer systems to coordinate and/or control the above components,
Human workers.
4.Components of a Manufacturing System
A manufacturing system consists of several
components:
Production machines plus tools, fixtures & other related hardware,
Material handling system,
Computer systems to coordinate and/or control the above components,
Human workers.
5. JOB SHOP Manufacturing System
Job shop systems are characterized by manufacturing of one or few quantity of products designed and produced as per the specification of customers within prefixed time and cost.
Characteristics:
The Job-shop manufacturing system is followed when there is:
High variety of products and low volume.
Use of general purpose machines and facilities.
Highly skilled operators who can take up each job as a challenge because of uniqueness.
Large inventory of materials, tools, parts.
Detailed planning is essential for sequencing the requirements of each product, capacities for each work center and order priorities.
Job shop systems are characterized by manufacturing of one or few quantity of products designed and produced as per the specification of customers within prefixed time and cost.
Characteristics:
The Job-shop manufacturing system is followed when there is:
High variety of products and low volume.
Use of general purpose machines and facilities.
Highly skilled operators who can take up each job as a challenge because of uniqueness.
Large inventory of materials, tools, parts.
Detailed planning is essential for sequencing the requirements of each product, capacities for each work center and order priorities.
6.Advantages:
Following are the advantages of job shop system:
Because of general purpose machines and facilities variety of products can be produced.
Operators will become more skilled and competent, as each job gives them learning opportunities.
Full potential of operators can be utilized.
Opportunity exists for creative methods and innovative ideas.
Limitations:
Following are the limitations of job shop system:
Higher cost due to frequent set up changes.
Higher level of inventory at all levels and hence higher inventory cost.
Production planning is complicated.
Larger space requirements.
Following are the advantages of job shop system:
Because of general purpose machines and facilities variety of products can be produced.
Operators will become more skilled and competent, as each job gives them learning opportunities.
Full potential of operators can be utilized.
Opportunity exists for creative methods and innovative ideas.
Limitations:
Following are the limitations of job shop system:
Higher cost due to frequent set up changes.
Higher level of inventory at all levels and hence higher inventory cost.
Production planning is complicated.
Larger space requirements.
7.BATCH Manufacturing System
Batch manufacturing is defined by American Production and Inventory Control Society (APICS) “as a form of manufacturing in which the job passes through the functional departments in lots or batches and each lot may have a different routing.” It is characterized by the manufacture of limited number of products produced at regular intervals and stocked awaiting sales.
Characteristics:
Batch manufacturing system is used :
When there is shorter production runs.
When plant and machinery are flexible.
When plant and machinery set up is used for the production of item in a batch and change of set up is required for processing the next batch.
When manufacturing lead time and cost are lower as compared to job order production.
Batch manufacturing is defined by American Production and Inventory Control Society (APICS) “as a form of manufacturing in which the job passes through the functional departments in lots or batches and each lot may have a different routing.” It is characterized by the manufacture of limited number of products produced at regular intervals and stocked awaiting sales.
Characteristics:
Batch manufacturing system is used :
When there is shorter production runs.
When plant and machinery are flexible.
When plant and machinery set up is used for the production of item in a batch and change of set up is required for processing the next batch.
When manufacturing lead time and cost are lower as compared to job order production.
8.Advantages:
Following are the advantages of batch production:
Better utilization of plant and machinery.
Promotes functional specialization.
Cost per unit is lower as compared to job order production.
Lower investment in plant and machinery.
Flexibility to accommodate and process number of products.
Job satisfaction exists for operators.
Limitations:
Following are the limitations of batch production:
Material handling is complex because of irregular and longer flows.
Production planning and control is complex.
Following are the advantages of batch production:
Better utilization of plant and machinery.
Promotes functional specialization.
Cost per unit is lower as compared to job order production.
Lower investment in plant and machinery.
Flexibility to accommodate and process number of products.
Job satisfaction exists for operators.
Limitations:
Following are the limitations of batch production:
Material handling is complex because of irregular and longer flows.
Production planning and control is complex.
9.MASS Production Manufacturing System
Manufacture of discrete parts or assemblies using a continuous process are called mass production.
Characteristics:
Mass production is used under the following circumstances:
Standardization of product and process sequence.
Dedicated special purpose machines having higher production capacities and output rates.
Large volume of products.
Shorter cycle time of production.
Lower in process inventory.
Perfectly balanced production lines.
Flow of materials, components and parts is continuous and without any back tracking.
Production planning and control is easy.
Material handling can be completely automatic.
Manufacture of discrete parts or assemblies using a continuous process are called mass production.
Characteristics:
Mass production is used under the following circumstances:
Standardization of product and process sequence.
Dedicated special purpose machines having higher production capacities and output rates.
Large volume of products.
Shorter cycle time of production.
Lower in process inventory.
Perfectly balanced production lines.
Flow of materials, components and parts is continuous and without any back tracking.
Production planning and control is easy.
Material handling can be completely automatic.
10.Advantages:
Following are the advantages of mass production:
Higher rate of production with reduced cycle time.
Higher capacity utilization due to line balancing.
Less skilled operators are required.
Low process inventory.
Manufacturing cost per unit is low.
Limitations:
Following are the limitations of mass production:
Breakdown of one machine will stop an entire production line.
Line layout needs major change with the changes in the product design.
High investment in production facilities.
The cycle time is determined by the slowest operation.
Following are the advantages of mass production:
Higher rate of production with reduced cycle time.
Higher capacity utilization due to line balancing.
Less skilled operators are required.
Low process inventory.
Manufacturing cost per unit is low.
Limitations:
Following are the limitations of mass production:
Breakdown of one machine will stop an entire production line.
Line layout needs major change with the changes in the product design.
High investment in production facilities.
The cycle time is determined by the slowest operation.
11.CELLULAR Manufacturing System
Rather than route the materials required through the entire plant, materials flow to the head of each work cell, through each process in the cell, then to final assembly. This eliminates most of the transportation and waiting we would see in the traditional approach.
Cellular manufacturing system is based on the concept of group layout.
Fixed Position Layout- All resources are brought at the job site.
Process Layout- Have different processing stations & job is brought at those stations.
Product Layout- Single piece flow of product through a sequence of machines placed as per product requirement.
Group Layout- combination of process & product layout, in cells.
12.Characteristics:
Combination of product & process layout.
The jobs are clubbed which are having similar properties.
One part family produced at one place.
Less material handling.
Rather than route the materials required through the entire plant, materials flow to the head of each work cell, through each process in the cell, then to final assembly. This eliminates most of the transportation and waiting we would see in the traditional approach.
Cellular manufacturing system is based on the concept of group layout.
Fixed Position Layout- All resources are brought at the job site.
Process Layout- Have different processing stations & job is brought at those stations.
Product Layout- Single piece flow of product through a sequence of machines placed as per product requirement.
Group Layout- combination of process & product layout, in cells.
12.Characteristics:
Combination of product & process layout.
The jobs are clubbed which are having similar properties.
One part family produced at one place.
Less material handling.
13.Advantages:
Following are the advantages of flexible manufacturing system:
More variety of products can be produced to cope up with consumer demand.
Better quality products.
Complex parts can be finished in one setting.
Reduction in non-productive & time lead time.
Save labor cost.
Limitations:
High setup cost.
Following are the advantages of flexible manufacturing system:
More variety of products can be produced to cope up with consumer demand.
Better quality products.
Complex parts can be finished in one setting.
Reduction in non-productive & time lead time.
Save labor cost.
Limitations:
High setup cost.
14.Computer Integrated Manufacturing System
Computer Integrated manufacturing is an interdisciplinary science applied to manufacturing. It involves the amalgamation of information science with automated manufacturing.
“CIM is the integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency.”
- By the Computer and Automation Systems Association of the Society of Manufacturing Engineers (CASA/SME).
Computer Integrated manufacturing is an interdisciplinary science applied to manufacturing. It involves the amalgamation of information science with automated manufacturing.
“CIM is the integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency.”
- By the Computer and Automation Systems Association of the Society of Manufacturing Engineers (CASA/SME).
15.ADVANCED Manufacturing Technology
Future trends include:-
AGILE Manufacturing
GREEN Manufacturing
VIRTUAL Manufacturing
The JUST-IN-TIME or KANBAN Approach
Future trends include:-
AGILE Manufacturing
GREEN Manufacturing
VIRTUAL Manufacturing
The JUST-IN-TIME or KANBAN Approach
16.Agile Manufacturing…
Agile manufacturing has been called the 21st-century manufacturing enterprise strategy.
By Agile, we mean the firm can quickly respond to market changes by quickly reengineering its business processes, reconfiguring its manufacturing systems, and innovating its products.
Green Manufacturing…
Green manufacturing aims at developing a manufacturing paradigm and methods for reducing pollution by a manufacturing firm.
Agile manufacturing has been called the 21st-century manufacturing enterprise strategy.
By Agile, we mean the firm can quickly respond to market changes by quickly reengineering its business processes, reconfiguring its manufacturing systems, and innovating its products.
Green Manufacturing…
Green manufacturing aims at developing a manufacturing paradigm and methods for reducing pollution by a manufacturing firm.
17.Virtual manufacturing…
By using virtual reality and high-performance simulation, virtual manufacturing focuses on building a digital model of the product and studies the dynamic and kinetic performance of the product to reduce product development cost and time.
Just-in-Time or Kanban Approach…
The objective of this recent trend in material control is to reduce the need for large, expensive inventories of material and sub-assemblies.
By requiring that external and internal suppliers deliver just the right items, at just the right place, at just the right time, this objective may be met.
By using virtual reality and high-performance simulation, virtual manufacturing focuses on building a digital model of the product and studies the dynamic and kinetic performance of the product to reduce product development cost and time.
Just-in-Time or Kanban Approach…
The objective of this recent trend in material control is to reduce the need for large, expensive inventories of material and sub-assemblies.
By requiring that external and internal suppliers deliver just the right items, at just the right place, at just the right time, this objective may be met.
18.Mass Production at Ford, 1907 - 1932
Key points:
“In mass production there are no fitters” - Henry Ford.
Stamping plays important role in providing low cost high precision parts.
Constant improvement, division of labor, standard work, flat organization. Moving assembly line (1913) comes from other examples in industry. Work pace is increased and turnover rate increases. In late 1913, to add 100 workers Ford needed to hire 963 people. $5/day pay is instituted to address this problem.
Vertical integration is taken to limits at River Rouge. End of previous cost cutting strategy, conveyor system limits flexibility, labor strike moves Ford to build new plants at other locations.
Conversion from Model T to Model A is too late and extremely painful, occasions 6 month shut down and great upheaval.
GM introduces yearly model change 1925-1932.
Key points:
“In mass production there are no fitters” - Henry Ford.
Stamping plays important role in providing low cost high precision parts.
Constant improvement, division of labor, standard work, flat organization. Moving assembly line (1913) comes from other examples in industry. Work pace is increased and turnover rate increases. In late 1913, to add 100 workers Ford needed to hire 963 people. $5/day pay is instituted to address this problem.
Vertical integration is taken to limits at River Rouge. End of previous cost cutting strategy, conveyor system limits flexibility, labor strike moves Ford to build new plants at other locations.
Conversion from Model T to Model A is too late and extremely painful, occasions 6 month shut down and great upheaval.
GM introduces yearly model change 1925-1932.
19.Common elements between
Ford and “Lean”
Elimination of Waste
Equipment Placed in the Sequence of Operations
Reduced Inventory
Production to Demand not to Stock
Continuous Improvement
Flat Organization
Ford and “Lean”
Elimination of Waste
Equipment Placed in the Sequence of Operations
Reduced Inventory
Production to Demand not to Stock
Continuous Improvement
Flat Organization
20.REFERENCES:
A Control Theorist's Perspective On Recent Trends In Manufacturing Systems, Stanley B. Gershwin, Richard R. Hildebrant , Rajan Suri , Sanjoy K. Mitter, 23rd IEEE Conference On Decision And Control, Las Vegas, Nevada
Advanced Manufacturing Technology , Module 5.2 Manufacturing Metrics, R.Siriram, January 2006.
Hiltomi, Manufacturing System Engineering, Tailor & Francis.
David A. Hounshell, From the American System to Mass Production, 1800-1932, The John Hopkin’s University, Press, 1984.
Karl Williams, Colin Haslam and John Williams; ‘Ford versus Fordism, The Beginning of Mass Production?’; Work, Employment and Society, December 1992.
A Control Theorist's Perspective On Recent Trends In Manufacturing Systems, Stanley B. Gershwin, Richard R. Hildebrant , Rajan Suri , Sanjoy K. Mitter, 23rd IEEE Conference On Decision And Control, Las Vegas, Nevada
Advanced Manufacturing Technology , Module 5.2 Manufacturing Metrics, R.Siriram, January 2006.
Hiltomi, Manufacturing System Engineering, Tailor & Francis.
David A. Hounshell, From the American System to Mass Production, 1800-1932, The John Hopkin’s University, Press, 1984.
Karl Williams, Colin Haslam and John Williams; ‘Ford versus Fordism, The Beginning of Mass Production?’; Work, Employment and Society, December 1992.
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