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What is called manufacturing system ? System: a set of components that are connected in a rational way to perform functions. Manufacturing systems are a system to make products. So making a product is the function of a manufacturing system. Resources are needed for a system to perform a function. Environments are needed for a system to perform a function. Manufacturing firms are a profit-based organization, so they have to consider the cost of making a product and the return they can get from selling their products
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Manufacturing Systems at the enterprise level
What is called manufacturing system ?
System: a set of components that are connected in a rational way to perform functions.
Manufacturing systems are a system to make products. So making a product is the function of a manufacturing system.
Resources are needed for a system to perform a function.
Environments are needed for a system to perform a function.
Manufacturing firms are a profit-based organization, so they have to consider the cost of making a product and the return they can get from selling their products
Manufacturing Systems: three levels
Logical (for each manufacturing firm or entity or system):
Firm level
Shop floor level
Machine level All our previous discussions are at the machine level. A machine is considered as a system that processes materials to make a product
Manufacturing Systems: three levels
Physical (for each manufacturing firm or entity or system):
Firm level
Shop floor level
Machine level
A manufacturing system can be one person with one machine. In this case, the three levels are flattened into one but this one physical entity has three logical functions.
Firm view of manufacturing systems
Materials
Capital equipment
Production tooling
Energy
Labor
Manufacturing Systems along with its process, e.g., business of repairing
Completed product
Scraps or wastes
Finance or money
Environment
Sustainability
Resilience
Health& Safety
Manufacturing systems at the enterprise level
Classification of manufacturing systems (firm level)
(1) project,
(2) job shop,
(3) repetitive,
(4) line and
(5) continuous
Manufacturing systems at the enterprise level
Project:
One of a kind (such as ship and nuclear power plant) Complex Site building (production tools must get to the site)
Job Shop:
Low volume and production quantities, called lot sizes Not site building (traditional workshop)
Process-based layout
Product-based layout
Manufacturing systems at the enterprise level
Repetitive:
Orders for repeat business approach 100%. Blanket contracts with customers for multiple years
occur frequently. Moderately high volume with lot sizes varying over
wide range. Fixed routing for products.
Remark: The system or plant is laid down in either process-based or product-based flow manner.
Manufacturing systems at the enterprise level
Line:
Delivery time (often called lead time) required by the
customer is often shorter than the total time it takes to build the
product.
Product has many different models and options.
An inventory of subassemblies is normally present.
Examples: Car and Truck.
System is laid down as a product-based flow manner.
Continuous:
Manufacturing lead time is greater than the lead time quoted to the customer.
Product demand is predicable. Product inventory is held. Volume is high. Products have few options.
Examples: Chemical components.
System is laid down in a product-based flow manner.
Characteristics of manufacturing Systems
Production strategy classification
To deals with how to market the product
Criteria for classification: customer lead time (CLD) and manufacturing lead time (MLD)
Engineer to order:
Product is either in the first stage of the life-cycle curve ora complex product with a unique design produced in single-digit quantities.
Example: construction industry (bridge, etc.)
Customer is willing to accept long MLD - permitting this strategy
Make to order:
All the engineering and design works are completed and the production process is proven.
Example: new residential homes.
The customer’s demand is unpredictable.
Assemble to order:
Primary reason of this strategy: MLD > CLD. Order is statistically predicable.
Examples; automobiles, personal computers
This strategy is especially adopted in the line manufacturing type
Make to stock:
- Reasons for this strategy: (1) CLD < MLD (2) product configuration has few options so that the demand can be predicated accurately.
- Product parts are often stocked in distribution warehouses located in major population centers.
Manufacturing systems at the enterprise level
Production strategy versus MLD:
Maximal MLD : ETO
Minimal MLD : MTS
It is important to be aware that the
production strategy can be changed with
the product evolution. MTO may not suit
the product which has a high component of
R&D; however MTO may be applied when
that product goes to maturity.
Enterprise organization
Aim: examine different function units and their communications
Manufacturing organization see Figure 1.6 where
boxes represent different function units and
arrowhead lines indicate the communications.
Architecture
Figure 1.6
Product and Process Definition (Figure 1.7)
Finance and management
Sales and Marketing
ProductionEngineering
Engineering release
ProductDesign
Manufacturing planning and control
Quality
Product design
Production engineering
Engineering release
Quality
Manufacturing planning and control(See Figure 1.8)
Manufacture process planningdetermine the type of machines required to process the parts and the production sequence, called the routing, to be used
Production planning -> scheduling (time factors included)
Manufacturing Planning and Control (MPC)
MPC versus others
Manufacturing systems at the enterprise level
Production sequence
