Lecture 1 Autom. of Manuf. Systems

MECT 3360 Automated Manufacturing Systems

Manufacturing systems andProduction concepts

Dr. Tafesse Borena

Information on the Blackboard Syllabus Schedule Updated regularly Homework will be available online PowerPoint will be available online

My cont InformationEmail tgborena@uh.edu

TAsRahul Avinash Email <ratatikonda@uh.eduVenkata Jayadeep Email

Syllabus Schedule Updated regularly Homework will be available online PowerPoint will be available online

My cont InformationEmail tgborena@uh.edu

TAsRahul Avinash Email <ratatikonda@uh.eduVenkata Jayadeep Email

Reference materialsText Book Automation, Production Systems, and Computer-Integrated

Manufacturing by Mikell P. Groover. (3rd Edition)

References Computer Aided Manufacturing by,

Tien-Chien Chang,Richard A.Wysk,Hsu-Pin Wang,

Copyright Declaration

Lectures materials are basically adopted from Mikell P. Grooverand Computer Aided Manufacturing by Tien-Chien Chang,Richard A.Wysk, and Hsu-Pin Wang,

Text Book Automation, Production Systems, and Computer-Integrated

Manufacturing by Mikell P. Groover. (3rd Edition)

References Computer Aided Manufacturing by,

Tien-Chien Chang,Richard A.Wysk,Hsu-Pin Wang,

Copyright Declaration

Lectures materials are basically adopted from Mikell P. Grooverand Computer Aided Manufacturing by Tien-Chien Chang,Richard A.Wysk, and Hsu-Pin Wang,

Course Objectives Automated manufacturing process planning and analysis,

including CNC programming, robotics, and elements ofcomputer-aided manufacturing

Automated manufacturing process planning and analysis,including CNC programming, robotics, and elements ofcomputer-aided manufacturing

Syllabus1. Manufacturing systems and Production concepts (1,2)2. Manufacturing Models and Metrics; Introduction to

Automation; 3, 4, 53. Hardware Components for Automation and Process

Control 64. Hardware Components of CNC machines and

principles of CNC programming 75. Industrial Robotics, Discrete Control Using PLC and

Personal Computers 8, 96. Material Handling System; Storage Systems 10, 11

1. Manufacturing systems and Production concepts (1,2)2. Manufacturing Models and Metrics; Introduction to

Automation; 3, 4, 53. Hardware Components for Automation and Process

Control 64. Hardware Components of CNC machines and

principles of CNC programming 75. Industrial Robotics, Discrete Control Using PLC and

Personal Computers 8, 96. Material Handling System; Storage Systems 10, 11

Syllabus8. Automatic Identification and Data Capture 129. Introduction to Manufacturing Systems; Single-Station

Manufacturing ells 13, 1410. Manual Assembly Lines, Automated Production Lines 15,

1611. Quality Programs for Manufacturing 20, 21, 2212. Automated Assembly Systems 17, 1813. Cellular Manufacturing and Flexible Manufacturing Systems

18, 1914. Product Design and CAD / CAM 2315. Production Planning And Control Systems; Just –In-Time And

Lean Production 25,26

8. Automatic Identification and Data Capture 129. Introduction to Manufacturing Systems; Single-Station

Manufacturing ells 13, 1410. Manual Assembly Lines, Automated Production Lines 15,

1611. Quality Programs for Manufacturing 20, 21, 2212. Automated Assembly Systems 17, 1813. Cellular Manufacturing and Flexible Manufacturing Systems

18, 1914. Product Design and CAD / CAM 2315. Production Planning And Control Systems; Just –In-Time And

Lean Production 25,26

Quiz – 1

1. Define Manufacturing and Manufacturing systems.(Explain how you understand these terms)

2. Describe the functions of Automation and the types ofautomations which you know.

3. Briefly explain the following terms ( a paragraph ortwo)

a. Computer Integrated manufacturingb. Flexible manufacturing systemsc. Computer Numerical Control Machines

1. Define Manufacturing and Manufacturing systems.(Explain how you understand these terms)

2. Describe the functions of Automation and the types ofautomations which you know.

3. Briefly explain the following terms ( a paragraph ortwo)

a. Computer Integrated manufacturingb. Flexible manufacturing systemsc. Computer Numerical Control Machines

Lecture outline

Manufacturing systems and Production concepts Realities of modern manufacturing systems Modern manufacturing approaches and technologies Concept and elements of a manufacturing system Functions of manufacturing support systems Three basic types of automation Automation in manufacturing systems Reasons for automation Automation principles and strategies Automation migration strategy

Manufacturing systems and Production concepts Realities of modern manufacturing systems Modern manufacturing approaches and technologies Concept and elements of a manufacturing system Functions of manufacturing support systems Three basic types of automation Automation in manufacturing systems Reasons for automation Automation principles and strategies Automation migration strategy

Distinctive realities of ModernManufacturing

Globalization

International outsourcing –

Local outsourcing -

Globalization

International outsourcing –

Local outsourcing -

Distinctive realities of ModernManufacturing Contract manufacturing –

Trend toward the service sector in the U.S.economy

Quality expectations –

Need for operational efficiency -

Contract manufacturing –

Trend toward the service sector in the U.S.economy

Quality expectations –

Need for operational efficiency -

Modern Manufacturing Approaches andTechnologies Automation –

Material handling technologies

Manufacturing systems -

Modern Manufacturing Approaches andTechnologies Flexible manufacturing –

Quality programs –

CIM – Lean production -

Production System Defined A collection of people, equipment, and procedures

organized to accomplish the manufacturing operations ofa company

Two categories: Facilities –

Manufacturing support systems

A collection of people, equipment, and proceduresorganized to accomplish the manufacturing operations ofa company

Two categories: Facilities –

Manufacturing support systems

The Production System.

Production System FacilitiesFacilities

Plant layout

Manufacturing systems – logical groupings of equipment andworkers in the factory Production line Stand-alone workstation and worker

Facilities

Plant layout

Manufacturing systems – logical groupings of equipment andworkers in the factory Production line Stand-alone workstation and worker

Manufacturing Systems in theProduction System

.

Manufacturing DefinedManufacturing is a collection of interrelated operationsand activities.

customer

marketing

accounting andfinancing

budget

stock of warehouse

purchasing

wholesaleand retail

engineeringdesign

planning andcontrol

manufacturing

qualitycontrol

Manufacturing production and processes

Manufacturing production is a series of processesadopted to fabricate a product.

Manufacturing processes are the lower-levelmanufacturing activities used to make products.

Manufacturing production is a series of processesadopted to fabricate a product.

Manufacturing processes are the lower-levelmanufacturing activities used to make products.

Manufacturing engineering and systems

Manufacturing engineering

Manufacturing system is an organization thatcomprises several interrelated manufacturingsubsets.

Components of a Manufacturing System1. Production machines

2. Material handling system

3. Computer system to coordinate and/or control thepreceding components

4. Human workers to operate and manage the system

1. Production machines

2. Material handling system

3. Computer system to coordinate and/or control thepreceding components

4. Human workers to operate and manage the system

Components of a Manufacturing System.

Marketing Accounting Financing

Design Manufacturing Product

Planning/Control

Manufacturing system diagram

Manufacturing SystemsFunctions encountered in most manufacturingsystems include: Product and process design product planning production operations management

planning and control material flow management and product

routing Layouting Accounting Personnel management Marketing

Functions encountered in most manufacturingsystems include: Product and process design product planning production operations management

planning and control material flow management and product

routing Layouting Accounting Personnel management Marketing

Manufacturing systems are generally quitecomplex, they almost involve

Manufacturing system functions can beperformed by humans or automated.

The following essential functions can beidentified in most manufacturing systems

Manufacturing Systems Manufacturing systems are generally quite

complex, they almost involve

Manufacturing system functions can beperformed by humans or automated.

The following essential functions can beidentified in most manufacturing systems

Manufacturing SystemsThree categories in terms of the human participationin the processes performed by the manufacturingsystem:

1. Manual work systems - a workerperforming one or more tasks without theaid of powered tools, but sometimes usinghand tools

2. Worker-machine systems - a workeroperating powered equipment

3. Automated systems - a process performedby a machine without direct participation ofa human

Three categories in terms of the human participationin the processes performed by the manufacturingsystem:

1. Manual work systems - a workerperforming one or more tasks without theaid of powered tools, but sometimes usinghand tools

2. Worker-machine systems - a workeroperating powered equipment

3. Automated systems - a process performedby a machine without direct participation ofa human

Manual Work System.

Worker-Machine System.

Automated System.

Manufacturing Support SystemsInvolves a cycle of information-processingactivities that consists of four functions:

1. Business functions - sales and marketing, orderentry, cost accounting, customer billing

2. Product design - research and development,design engineering, prototype shop

3. Manufacturing planning - process planning,production planning, MPS,MRP, capacityplanning

4. Manufacturing control - shop floor control,inventory control, quality control

Involves a cycle of information-processingactivities that consists of four functions:

1. Business functions - sales and marketing, orderentry, cost accounting, customer billing

2. Product design - research and development,design engineering, prototype shop

3. Manufacturing planning - process planning,production planning, MPS,MRP, capacityplanning

4. Manufacturing control - shop floor control,inventory control, quality control

Information Processing Cycle inManufacturing Support Systems.

Automation in Production SystemsTwo categories of automation in the productionsystem:

1. Automation of manufacturing systems in thefactory

2. Computerization of the manufacturingsupport systems

CIM-.

Two categories of automation in the productionsystem:

1. Automation of manufacturing systems in thefactory

2. Computerization of the manufacturingsupport systems

CIM-.

Computer Integrated Manufacturing.

Automated Manufacturing SystemsExamples: 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

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

Automated Manufacturing SystemsThree basic types:

1. Fixed automation2. Programmable automation3. Flexible automation

Fixed AutomationA manufacturing system in which the sequence ofprocessing (or assembly) operations is fixed by theequipment configurationTypical features:

Programmable AutomationA manufacturing system designed with the capabilityto change the sequence of operations toaccommodate different product configurationsTypical features:

Flexible AutomationAn extension of programmable automation in which thesystem is capable of changing over from one job to thenext with no lost time between jobsTypical features:

Product Variety and ProductionQuantity for Three Automation Types.

Computerized Manufacturing SupportSystemsWhy to automate the manufacturing supportsystems:

Reasons for Automating1. To increase labor productivity2. To reduce labor cost3. To mitigate the effects of labor shortages4. To reduce or remove routine manual and clerical

tasks5. To improve worker safety6. To improve product quality7. To reduce manufacturing lead time8. To accomplish what cannot be done manually9. To avoid the high cost of not automating

1. To increase labor productivity2. To reduce labor cost3. To mitigate the effects of labor shortages4. To reduce or remove routine manual and clerical

tasks5. To improve worker safety6. To improve product quality7. To reduce manufacturing lead time8. To accomplish what cannot be done manually9. To avoid the high cost of not automating

Manual Labor in Production Systems

Is there a place for manual labor in the modernproduction system? Answer:YES

Two aspects:1. Manual labor in factory operations2. Labor in manufacturing support systems

Is there a place for manual labor in the modernproduction system? Answer:YES

Two aspects:1. Manual labor in factory operations2. Labor in manufacturing support systems

Manual Labor in Factory OperationsThe long term trend is toward greater use ofautomated systems to substitute for manuallabor When is manual labor justified?

Labor in Manufacturing SupportSystems 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

Product designers who bring creativity to thedesign 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

Automation Principles and Strategies

1. The USA Principle2. Ten Strategies for Automation and Process

Improvement3. Automation Migration Strategy

1. The USA Principle2. Ten Strategies for Automation and Process

Improvement3. Automation Migration Strategy

U.S.A Principle1. Understand the existing process

2. Simplify the process

3. Automate the process

1. Understand the existing process

2. Simplify the process

3. Automate the process

Ten Strategies for Automation andProcess Improvement

1. Specialization of operations2. Combined operations3. Simultaneous operations4. Integration of operations5. Increased flexibility6. Improved material handling and storage7. On-line inspection8. Process control and optimization9. Plant operations control10. Computer-integrated manufacturing

1. Specialization of operations2. Combined operations3. Simultaneous operations4. Integration of operations5. Increased flexibility6. Improved material handling and storage7. On-line inspection8. Process control and optimization9. Plant operations control10. Computer-integrated manufacturing

Automation Migration Strategy An automation migration strategy, or

It has the advantage of being graduated, as

Typically it contains the follow three steps:

An automation migration strategy, or

It has the advantage of being graduated, as

Typically it contains the follow three steps:

Automation Migration StrategyFor Introduction of New Products1. Phase 1 – Manual production

2. Phase 2 – Automated production

3. Phase 3 – Automated integrated production

1. Phase 1 – Manual production

2. Phase 2 – Automated production

3. Phase 3 – Automated integrated production

.

AutomationMigrationStrategy

Summary Production systems Manufacturing, manufacturing engineering, manufacturing

systems Classifications of manufacturing systems Functions of manufacturing support systems Computer integrated manufacturing Manual labor in manufacturing Reason for automation Types of automation Automation principles and strategies Automation migration strategy (for new products)

Production systems Manufacturing, manufacturing engineering, manufacturing

systems Classifications of manufacturing systems Functions of manufacturing support systems Computer integrated manufacturing Manual labor in manufacturing Reason for automation Types of automation Automation principles and strategies Automation migration strategy (for new products)

Review Question1. What is meant by a production system, and what categories of

production system are generally specified?2. Manufacturing systems depend for their operation on the

interaction of manual labour and automation. What are thecategories of manual labour / automation that can be identified?What mode of automation do these categories usually operate in?

3. Define briefly computer-integrated manufacturing.4. When is automation used in a manufacturing system?5. Describe the three types of automation that can be used in a

manufacturing system.6. Manual labour is used alongside automation in production

systems. Name a number of the issues that affect the use ofmanual labour in production systems.

7. What elements should a strategy for automation implementationconsider?

1. What is meant by a production system, and what categories ofproduction system are generally specified?

2. Manufacturing systems depend for their operation on theinteraction of manual labour and automation. What are thecategories of manual labour / automation that can be identified?What mode of automation do these categories usually operate in?

3. Define briefly computer-integrated manufacturing.4. When is automation used in a manufacturing system?5. Describe the three types of automation that can be used in a

manufacturing system.6. Manual labour is used alongside automation in production

systems. Name a number of the issues that affect the use ofmanual labour in production systems.

7. What elements should a strategy for automation implementationconsider?

MECT 3360 Automated Manufacturing Systems

Manufacturing Operations

Dr. Tafesse Borena

Manufacturing Operations1. Manufacturing Industries and Products2. Manufacturing Operations3. Production Facilities4. Product/Production Relationships5. Lean Production

1. Manufacturing Industries and Products2. Manufacturing Operations3. Production Facilities4. Product/Production Relationships5. Lean Production

Manufacturing Defined TechnologicalDefinition

Application of physical and chemical processes to alterthe geometry, properties, and/or appearance of a givenstarting material to make parts or products

Manufacturing also includes the joining of multipleparts to make assembled products

Accomplished by a combination of machinery, tools,power, and manual labor.

Almost always carried out as a sequence of operations

Application of physical and chemical processes to alterthe geometry, properties, and/or appearance of a givenstarting material to make parts or products

Manufacturing also includes the joining of multipleparts 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 - TechnologicalDefinition

.

Manufacturing Defined -Economic Definition

Transformation of materials into items of greater value bymeans of one or more processing and/or assemblyoperations

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

Transformation of materials into items of greater value bymeans of one or more processing and/or assemblyoperations

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.

Classification of Industries1. Primary industries – cultivate and exploit natural

resources Examples: agriculture, mining

2. Secondary industries – convert output of primaryindustries into products Examples: manufacturing, power generation,

construction

3. Tertiary industries – service sector Examples: banking, education, government, legal services,

retail trade, transportation

1. Primary industries – cultivate and exploit naturalresources Examples: agriculture, mining

2. Secondary industries – convert output of primaryindustries into products Examples: manufacturing, power generation,

construction

3. Tertiary industries – service sector Examples: banking, education, government, legal services,

retail trade, transportation

Manufacturing IndustriesInternational Standard Industrial Classification

ISIC Code Food, beverages, tobacco 31 Textiles, apparel, leather and fur products 32 Wood and wood products, cork 33 Paper, printing, publishing, bookbinding 34 Chemicals, coal, petroleum, & their products 35 Ceramics, glass, mineral products 36 Basic metals, e.g., steel, aluminum 37 Fabricated products, e.g., cars, machines, etc. 38 Other products, e.g., jewelry, toys 39

International Standard Industrial ClassificationISIC Code

Food, beverages, tobacco 31 Textiles, apparel, leather and fur products 32 Wood and wood products, cork 33 Paper, printing, publishing, bookbinding 34 Chemicals, coal, petroleum, & their products 35 Ceramics, glass, mineral products 36 Basic metals, e.g., steel, aluminum 37 Fabricated products, e.g., cars, machines, etc. 38 Other products, e.g., jewelry, toys 39

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 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 Industries andDiscrete Manufacturing Industries

Manufacturing Operations There are certain basic activities that must be carried

out in a factory to convert raw materials into finishedproducts

For discrete products:1. Processing and assembly operations2. Material handling3. Inspection and testing4. Coordination and control

There are certain basic activities that must be carriedout in a factory to convert raw materials into finishedproducts

For discrete products:1. Processing and assembly operations2. Material handling3. Inspection and testing4. Coordination and control

.

Classification ofmanufacturingprocesses

Processing Operations Shaping operations

1. Solidification processes2. Particulate processing3. Deformation processes4. Material removal processes

Property-enhancing operations (heat treatments) Surface processing operations

Cleaning and surface treatments Coating and thin-film deposition

Shaping operations1. Solidification processes2. Particulate processing3. Deformation processes4. Material removal processes

Property-enhancing operations (heat treatments) Surface processing operations

Cleaning and surface treatments Coating and thin-film deposition

Assembly Operations

Joining processes Welding Brazing and soldering Adhesive bonding

Mechanical assembly Threaded fasteners (e.g., bolts and nuts, screws) Rivets Interference fits (e.g., press fitting, shrink fits) Other

Joining processes Welding Brazing and soldering Adhesive bonding

Mechanical assembly Threaded fasteners (e.g., bolts and nuts, screws) Rivets Interference fits (e.g., press fitting, shrink fits) Other

Other Factory Operations

Material handling and storage Inspection and testing Coordination and control

Material Handling Material transport Vehicles, e.g., forklift trucks, AGVs, monorails Conveyors Hoists and cranes

Storage systems Unitizing equipment Automatic identification and data capture Bar codes RFID (Radio Frequency Identification) Other AIDC (Automatic Identification and Capture)

Material transport Vehicles, e.g., forklift trucks, AGVs, monorails Conveyors Hoists and cranes

Storage systems Unitizing equipment Automatic identification and data capture Bar codes RFID (Radio Frequency Identification) Other AIDC (Automatic Identification and Capture)

Time Spent in Material Handling.

Inspection and Testing

Inspection – examination of the product and itscomponents to determine whether they conform todesign specifications Inspection for variables - measuring Inspection of attributes – gaging

Testing – observing the product (or part, material,subassembly) during actual operation or underconditions that might occur during operation

Inspection – examination of the product and itscomponents to determine whether they conform todesign specifications Inspection for variables - measuring Inspection of attributes – gaging

Testing – observing the product (or part, material,subassembly) during actual operation or underconditions that might occur during operation

Coordination and Control

Regulation of the individual processing and assemblyoperations Process control Quality control

Management of plant level activities Production planning and control Quality control

Regulation of the individual processing and assemblyoperations Process control Quality control

Management of plant level activities Production planning and control Quality control

Production Facilities

A manufacturing company attempts to organize itsfacilities in the most efficient way to serve the particularmission of the plant

Certain types of plants are recognized as the mostappropriate way to organize for a given type ofmanufacturing

The most appropriate type depends on: Types of products made Production quantity Product variety

A manufacturing company attempts to organize itsfacilities in the most efficient way to serve the particularmission of the plant

Certain types of plants are recognized as the mostappropriate way to organize for a given type ofmanufacturing

The most appropriate type depends on: Types of products made Production quantity Product variety

Production QuantityNumber of units of a given part or product produced

annually by the plant Three quantity ranges:

1. Low production – 1 to 100 units2. Medium production – 100 to 10,000 units3. High production – 10,000 to millions of units

Number of units of a given part or product producedannually by the plant

Three quantity ranges:1. Low production – 1 to 100 units2. Medium production – 100 to 10,000 units3. High production – 10,000 to millions of units

Product Variety

Refers to the number of different product or partdesigns or types produced in the plant

Inverse relationship between production quantity andproduct variety in factory operations

Product variety is more complicated than a number Hard product variety – products differ greatly Few common components in an assembly

Soft product variety – small differences between products Many common components in an assembly

Refers to the number of different product or partdesigns or types produced in the plant

Inverse relationship between production quantity andproduct variety in factory operations

Product variety is more complicated than a number Hard product variety – products differ greatly Few common components in an assembly

Soft product variety – small differences between products Many common components in an assembly

Product Variety vs.Production Quantity

.

Low Production Quantity

Job shop – makes low quantities of specialized andcustomized products

Also includes production of components for theseproducts

Products are typically complex (e.g., specializedmachinery, prototypes, space capsules)

Equipment is general purpose Plant layouts: Fixed position Process layout

Job shop – makes low quantities of specialized andcustomized products

Also includes production of components for theseproducts

Products are typically complex (e.g., specializedmachinery, prototypes, space capsules)

Equipment is general purpose Plant layouts: Fixed position Process layout

Fixed-Position Layout.

Process Layout.

Medium Production Quantities1. Batch production – A batch of a given product is

produced, and then the facility is changed over toproduce another product Changeover takes time – setup time Typical layout – process layout Hard product variety

2. Cellular manufacturing – A mixture of products is madewithout significant changeover time between products Typical layout – cellular layout Soft product variety

1. Batch production – A batch of a given product isproduced, and then the facility is changed over toproduce another product Changeover takes time – setup time Typical layout – process layout Hard product variety

2. Cellular manufacturing – A mixture of products is madewithout significant changeover time between products Typical layout – cellular layout Soft product variety

Cellular Layout.

High Production1. Quantity production – Equipment is dedicated to the

manufacture of one product Standard machines tooled for high production (e.g.,

stamping presses, molding machines) Typical layout – process layout

2. Flow line production – Multiple workstations arrangedin sequence Product requires multiple processing or assembly steps Product layout is most common

1. Quantity production – Equipment is dedicated to themanufacture of one product Standard machines tooled for high production (e.g.,

stamping presses, molding machines) Typical layout – process layout

2. Flow line production – Multiple workstations arrangedin sequence Product requires multiple processing or assembly steps Product layout is most common

Product Layout.

Relationships between Plant Layoutand Type of Production Facility

.

Product/Production Relationships

Total number of product units = Qf = Product variety Hard product variety = differences between products Soft product variety = differences between models of

products

Product and part complexity Product complexity np = number of parts in product Part complexity no = number of operations per part

Refer to Table 2.6 for np and no values

P

jjQ

1

Total number of product units = Qf = Product variety Hard product variety = differences between products Soft product variety = differences between models of

products

Product and part complexity Product complexity np = number of parts in product Part complexity no = number of operations per part

Refer to Table 2.6 for np and no values

Factory Operations Model If all the products are manufactured in the plant then the

total number of processing operations performed by theplant is

Simplified for purposes of conceptualization: taking average P, Q, np and no

Total number of product units Qf = PQ Total number of parts produced npf = PQnp

Total number of operations nof = Pqnpno

Where Total number of operations cycle performed in the factory nof Number of processing operation(for each part summed over the number

parts in product j, npj ) - nojk Product complexity np = number of parts in product Part complexity no = number of operations per part

pjn

kojk

p

jpjjof nnQn

11

If all the products are manufactured in the plant then thetotal number of processing operations performed by theplant is

Simplified for purposes of conceptualization: taking average P, Q, np and no

Total number of product units Qf = PQ Total number of parts produced npf = PQnp

Total number of operations nof = Pqnpno

Where Total number of operations cycle performed in the factory nof Number of processing operation(for each part summed over the number

parts in product j, npj ) - nojk Product complexity np = number of parts in product Part complexity no = number of operations per part

ExampleA Company is planning a new product line and will build a newplant to manufacture the parts for a new product line. Theproduct line will include 50 different models. Annual production ofeach model is expected to be 1000 units. Each product will beassembled of 400 components. All processing of parts will beaccomplished in one factory. There are an average of 6 processingsteps required to produce each component., determine totalnumber of processing operations performed by the plant.

A Company is planning a new product line and will build a newplant to manufacture the parts for a new product line. Theproduct line will include 50 different models. Annual production ofeach model is expected to be 1000 units. Each product will beassembled of 400 components. All processing of parts will beaccomplished in one factory. There are an average of 6 processingsteps required to produce each component., determine totalnumber of processing operations performed by the plant.

Limitations and Capabilities of aManufacturing Plant

Manufacturing capability - the technical and physicallimitations of a manufacturing firm and each of its plants Three dimensions of manufacturing capability:

1. Technological processing capability - the available set ofmanufacturing processes

2. Physical size and weight of product3. Production capacity (plant capacity) - production quantity that

can be made in a given time (eg annual tonnes of steelproduced, number of ships built, etc,)

Manufacturing capability - the technical and physicallimitations of a manufacturing firm and each of its plants Three dimensions of manufacturing capability:

1. Technological processing capability - the available set ofmanufacturing processes

2. Physical size and weight of product3. Production capacity (plant capacity) - production quantity that

can be made in a given time (eg annual tonnes of steelproduced, number of ships built, etc,)

Lean ProductionLean –

Resources

Also implies completing products in the minimum possibletime and achieving a very high quality level to completelysatisfy the customer

In short, lean production means doing more with less, anddoing it better

Lean –

Resources

Also implies completing products in the minimum possibletime and achieving a very high quality level to completelysatisfy the customer

In short, lean production means doing more with less, anddoing it better

Lean Production andManufacturing ActivitiesManufacturing activities can be divided into three categoriesaccording to the value they contribute to the productmade :1. Value-adding activities

2. Auxiliary activities –

3. Wasteful activities -

Manufacturing activities can be divided into three categoriesaccording to the value they contribute to the productmade :1. Value-adding activities

2. Auxiliary activities –

3. Wasteful activities -

Programs Associated withLean Production

Just-in-time delivery of parts Worker involvement Continuous improvement Reduced setup times Stop the process when something is wrong Error prevention Total productive maintenance

Just-in-time delivery of parts Worker involvement Continuous improvement Reduced setup times Stop the process when something is wrong Error prevention Total productive maintenance