Production System organized to accomplish the manufacturing operations of a company. Production System is the collection of people equipment procedures Manufacturing Support System Facilities Factory Equipment Production System Manufacturing Support System set of procedures used by the company to manage production solve problems (technical, logistic) moving work through the factory quality standards product design information technology Facilities the factory the equipment in the factory production machines & tooling material handling equipment inspection equipment computer that control mfg. ops. the way the equipment is organized plant layout In modern manufacturing operations, portions of the Production System are automated and/or computerized. IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Manufacturing Systems are logical groupings of facilities, workers, and policies. work station individual work cells: a worker assigned to that machine a single production machine Although there are minor differences we will use the terms work cell, work center, work station interchangably. a production line: workstations connected by a conveyor IE321 Industrial Production Systems – Fall 2017

Production System - Facilities A manufacturing company attempts to organize its facilities in the most efficient way to serve the particular mission of that plant. Over the years, certain types of production facilities have come to be recognized as the most appropriate way to organize for a given type of manufacturing. Production Quantity : number of units of a given part or product produced annually Product Variety different product designs or types that are produced in a plant (shape, size, style, function, market focus, components, ...) : Product Variety Low Medium High 1 100 10,000 1,000,000 Production Quantity IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Hard Product Variety different product categories Ex: car vs truck Soft Product Variety within the same prod. category Ex: models of cars from the same company sedan, hatchback, convertible, ... may use the same production line for all models Variety is less quantitative than Quantity. Common parts is an indicator of lack of variety (namely an indcator of similarity). Work Organization usually depends on the Product Variety. Throughout this course the type of products we will be interested in are discrete parts not fluids or bulk. These products require certain types of operations such as shaping, forming, transformations, and assembly. IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Low Quantity Production 1-100 units/year “Job Shop” Fixed Position Layout Process Layout Medium Quantity Production 100 - 10,000 units/year “Batch Shop” Batch Production Cellular Production High Quantity Production 10,000 - millions units/year “Flow Shop” Quantity Production Flow Line Production IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Low Quantity Production Job Shop specialized and customized products part & product variations are quite wide typically complex products space capsules boats and ships aircrafts heavy machinery special machinery locomotives and wagons can be also component parts for products special orders, repeat orders may not occur equipment: general purpose labor force: highly skilled facilities: designed for maximum flexibility Layout Types Fixed Position Layout Process Layout IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Low Quantity Production: Fixed Position Layout workers and equipment are brought to the product mobile equipment product workers IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Low Quantity Production: Fixed Position Layout large and heavy products remain in a single location workers and equipment are brought to the product (may also build in large modules at different locations then bring together for final assembly) IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Low Quantity Production: Process Layout arrangement of facility/equipment/machines according to function Lathe Department Grinding Department Painting Department Drilling Department Milling Department IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Low Quantity Production: Process Layout equipment is arranged according to function or type may be used for producing components of large products. For example each in one department lathing boring sheet metal work welding grinding cutting milling heat treatment painting different parts requiring different operation sequences are routed through the departments in the particular order needed for their processing, usually in batches Pros: flexibility, great variety of alternative operation sequences for different part configurations Cons: the machinery and methods to produce a part are not designed for high efficiency much material handling is required to move parts between departments work-in-progress (WIP), also called in-process-inventory can be high IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Medium Quantity Production facility is changed over to produce a batch of the next product, after one batch is made orders for products are frequently repeated equipment capacity can be shared among multiple products Setups (changeovers) between products take time (waste of prod.capacity) change tooling test run setup the machine calibrate reprogram the machine supervisor need Process Layout is usually used IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Medium Quantity Production: Batch Production product variety hard make-to-Stock situations items are made to replenish inventory to be gradually depleted by demand Process Layout is used IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Medium Quantity Production: Cellular Production product variety soft Cell #1 Cell #2 Cell #3 Cell #4 IE321 Industrial Production Systems – Fall 2017

Production System - Facilities Medium Quantity Production: Cellular Production no extensive changeovers between products the equipment is configured so that groups of similar parts or products can be made on the same equipment without siginificant loss of time for changeovers processing or assembly of different parts or products is accomplished in cells consisting of several workstations or machines cells are designed to produce a limited variety of products specialized in production of a given set of similar parts or products Group Technology: clustering parts + designing cells Cellular Layout is used IE321 Industrial Production Systems – Fall 2017

Production System - Facilities High Quantity Production mass production production facility is dedicated to the manufacture of a product with high demand rate almost no product variety standard products Quantity Production Flow Line Production IE321 Industrial Production Systems – Fall 2017

Production System - Facilities High Quantity Production: Quantity Production single part on single pieces of equipment standard machines (stamping press) equipped with special tooling (dies and material handling devices) in effect dedicating the equipment to the production of one part type for example: nuts & bolts Process Layout is used typically product 2 product 1 IE321 Industrial Production Systems – Fall 2017

Production System - Facilities High Quantity Production: Flow Line Production multiple workstations arranged in sequence parts or assemblies are physically moved through the sequence to complete the product workstations consist of production machines and/or workers equipped with specialized tools the collection of stations is designed specifically for the product to maximize efficiency Product Layout is used IE321 Industrial Production Systems – Fall 2017

Production System - Facilities High Quantity Production: Flow Line Production Example: assembly line (cars, household appliences) pure flow line: no variations in the products made on the line single model production line (each product is identical) model variations, styles, options are needed to increase marketability suiting the individual customer’s taste mixed model production/assembly line: soft variety is made on the line (modern automobile industry, same basic design, different nameplates, options, variations coming from the same line) IE321 Industrial Production Systems – Fall 2017

Production System - Facilities fixed position layout process layout Job Shop Product Variety cellular layout Batch Production Cellular Manufacturing product layout Quantity Flowline Mass Production 1 100 10,000 1,000,000 Production Quantity IE321 Industrial Production Systems – Fall 2017

Manufacturing Support Systems Facilities Factory Equipment Production System A manufacturing company organizes its facilities in the most efficient way to serve its mission -Design the processes and equipment -Plan and Control the production orders -Satisfy Product Quality Requirements Manufacturing Support Systems include people and procedures by which a company manages its production operations. They do not necessarily come in contact with the product but plan and control its progress through the factory IE321 Industrial Production Systems – Fall 2017

Manufacturing Support Systems Business Functions marketing forecasting order entry cost accounting customer billing types of customer orders: manufacture to customer’s specs manufacturer’s proprietary products internal order based on a forecast Product Design Research&Development Drafting/Prototype Shop Design Engineering types of product design: customer design customer specification proprietary product Manufacturing Planning Process Planning Master Production Schedule Materials Requirements Planning Capacity Planning Manufacturing Control Shop Floor Control Inventory Control Quality Control Customer order Production System Facilities IE321 Industrial Production Systems – Fall 2017

Automation Automation in Production Systems technology concerned with application of mechanical, electronic, and computer based systems to operate and control parts of or the entire production with reduced or no human input Automation of the manufacturing systems in the factory floor are often implemented by computer systems (but not necessarily) Automation of the manufacturing support systems are always computerized such as sales forecasting, customer relations, product design, process design, manufacturing planning and control Both systems are connected to the computerized manufacturing support systems and management information systems operating at the plant and enterprise levels. This extensive use of computers computers in production systems is often referred to as Computer Integrated Manufacturing. IE321 Industrial Production Systems – Fall 2017

Potential Computerization Automation Production System Computer Integrated Manufacturing Potential Computerization Applications Potential Automation Manufacturing Support System Facilities Factory Equipment IE321 Industrial Production Systems – Fall 2017

Automation Automated Manufacturing Systems perform their operations with reduced level of human participation compared with their corresponding manual processes. − automated machine tools that process parts (processing) − transfer lines performing a series of machining operations − automated assembly (assembly) − manufacturing systems that use industrial robots to perform processing and/or assembly operations − automatic material handling and storage systems to integrate mfg. ops − automatic inspection systems for quality control or combination of processing, assembly, inspection, and material handling within the same system There are three basic types: Fixed Automation Programmable Automation Flexible Automation IE321 Industrial Production Systems – Fall 2017

Automation Fixed Automation sequence of processing/assembly operations are fixed by the equipment configuration. Each of the operations in the sequence is usually simple such as linear or rotational movement or a combination of the two. Integration and coordination of many such operations into one piece of equipment makes the system complex. Example: feeding a rotating spindle −high initial investment for custom-engineered equipment −high production rates −relatively inflexible in accomodating product variety economical justification is the large quantities and high production rates IE321 Industrial Production Systems – Fall 2017

Automation Programmable Automation capability to change sequence of operations to accomodate different product configurations. Operation sequence is controlled by a program, a set of coded instructions. New programs can be prepared and entered into the equipment. Example: computer numerical control (CNC) milling machine, industrial robots, programmable logic controllers − high initial investment in general purpose equipment − lower production rates than fixed automation − flexibility to deal with variations and changes in product configurations − suitable for low and medium volume batch production Each batch requires reprogramming and a changeover: reprogramming, altering the physical setup, loading tools, attaching fixtures, adjusting machine settings. Typical cycle involves: setup + production IE321 Industrial Production Systems – Fall 2017

Automation Flexible Automation capability to produce a variety of parts or products with virtually no time lost for changeovers from one style to the next. No need to use batch production. The differences between parts processed by the system should not be significant, soft variety. Example: flexible manufacturing systems (FMS) dating back to late 1960s − high initial investment for custom engineered systems − continuous production of variable mixture of products − medium production rates − flexibility to deal with product design variations IE321 Industrial Production Systems – Fall 2017

Programmable Automation Product Variety Programmable Automation Flexible Automation Manual Production Fixed Automation 1 100 10,000 1,000,000 Production Quantity IE321 Industrial Production Systems – Fall 2017

Computer Integrated Manufacturing Abbreviated as CIM, Computer Integrated Manufacturing is the designing of the products planning the production controling the operations performing various business related functions pervasive use of computers in aims at reducing the amount of manual and clerical effort ideally true CIM integrates all of these functions in one system throughout the enterprise CAD – the use computers to support the product design function CAM – the use of computers to support manufacturing engineering such as process planning or numerical control part programming CIM = CAD/CAM + manufacturing related business functions IE321 Industrial Production Systems – Fall 2017

Computerized MSS Product Design Manufacturing Planning Business Raw Materials Finished Products Manufacturing Planning Product Design Business Functions Control Factory Operations: Processing Material handling Inspection, etc IE321 Industrial Production Systems – Fall 2017

Reasons for Automating Increasing the level of automation is not necessarily the right direction for a given production situation. Here are some of the reasons used to justify automation: 1. To increase labor productivity 2. To reduce labor cost 3. To mitigate the effects of labor shortages 4. To reduce or eliminate routine manual and clerical tasks 5. To improve worker safety 6. To improve product quality 7. To reduce manufacturing lead time 8. To accomplish processes that cannot be done manually 9. To avoid the cost of not automating IE321 Industrial Production Systems – Fall 2017

Manual Labor Manual labor will be required, for the foreseeable future, to manage and maintain the plant even in those cases where they do not participate in directly in its manufacturing operations. Manual Labor in Factory Operations There is a long term trend of greater use of automated machines and every reason to believe the trend will continue. Economics, namely hourly labor cost, is still the major determinant. Average wages in some countries are so low, most automation projects are impossible to justify on the basis of cost reduction (Mexico, China, India, so on). Other reasons not to automate: 1. Task is too technologically difficult to automate Physical access to work location Adjustments required in the task Manual dexterity requirements Demands on hand eye coordination 2. Short product life cycle Design and introduction time is too short Product on the market for a short period of time Tooling for manual production vs automation IE321 Industrial Production Systems – Fall 2017

Manual Labor Manual Labor in Factory Operations 3. Customized product One of a kind item, unique features Manual labor is versatile and adaptable, more flexible than any machine 4. To cope with ups and downs in demand Manual labor can be added or reduced much easier than automated machines, automated systems have upper limits on their capacity Fixed cost of automation must be spread over fewer units when demand is low 5. To reduce the risk of product failure Introduction of a new product, the ultimate success of the product is uncertain. The risk of losing a significant investment in automation if the product fails to achieve a long market life. IE321 Industrial Production Systems – Fall 2017

Manual Labor Manual Labor in Manufacturing Support Systems In manufacturing support systems, many of the routine manual and clerical tasks can be automated using computer systems. Similar to production automation, use of computers in this case, increases productivity and improves quality. Example: MRP, order releases for component parts based on the master production schedule for final products (massive amount of data processing). Humans are still needed to interpret and implement the output of MRP computations Example: CAD, assists amplifies designer’s creative talents Example: Computer Aided Process Planning, plan production methods and routings IE321 Industrial Production Systems – Fall 2017

Manual Labor Tasks we cannot automate: decision making, learning, engineering, evaluating, managing. Relative Strengths of Humans Relative Strengths of Machines Sense unexpected stimuli Perform repetitive tasks consistently Develop new solutions to problems Store large amounts of data Cope with abstract problems Retrieve data from memory reliably Adapt to change Perform multiple tasks at same time Generalize from observations Apply high forces and power Learn from experience Perform simple computations quickly Make difficult decisions based on Make routine desicions quickly incomplete data IE321 Industrial Production Systems – Fall 2017

Manual Labor Kinds of tasks that still need human labor even if all the manufacturing systems in the factory are automated: Equipment Maintenance maintain, repair, preventive maintenance Programming and Computer Operations upgrades, new program installations, execute programs Engineering Project Work continual need to upgrade production machines, design tooling, continuous improvement projects Plant Management running the factory more emphasis on the managers technical skills not the personnel skills IE321 Industrial Production Systems – Fall 2017

Automation Principles USA Principle – Understand, Simplify, Automate Understand The Existing Process inputs? outputs? what exactly happens in between? what is the function of the process? how does it add value to the product? what are the upstream and downstream operations in the production sequence, and can they be combined with this process? number of steps in the process number and placement of inspections number of moves and delays time spent in storage mathematical/numerical modeling input/output variables operating parameters, environmental conditions, process settings the relationship among the parameters and variables process control, quality control, planning&control IE321 Industrial Production Systems – Fall 2017

Automation Principles USA Principle Simplify The Process what is the purpose? is it necessary? can it be eliminated? is this the most appropriate technology? how can it be simplified? combine some of the steps, perform some steps simultaneously, integrate some of the steps into a production line Automate The Process once the process has been reduced to its simplest form automation may become unnecessary or may not be cost justified anymore, otherwise go ahead with automation automation migration strategy might be implemented IE321 Industrial Production Systems – Fall 2017

Automation and Production Strategies Ten Strategies for Automation and Production Systems 1. Specialization of Operations design a tool/machine to do one operation with greater efficiency yield, quality, production rate 2. Combined Operations perform more than one operation at a given machine decreases the number of transports (reduced material handling effort) reduces the number of separate machines needed reduces the total setup time (since using fewer number of machines) 3. Simultaneous Operations perform two or more operations simultaneously (transport + assemble) requires more resources or investment reduces total processing time 4. Integration of Operations link several workstations together into a single integrated mechanism (use automated work handling devices to transfer parts b/w stations) (a small production line) IE321 Industrial Production Systems – Fall 2017

Automation and Production Strategies Ten Strategies for Automation and Production Systems 5. Increased Flexibility maximize utilization of equipment (jobshop medium volume) by using the same equipment for a variety of parts or products, involves use of the flexible automation concepts reduce the setup time and programming time for the machines 6. Improved Material Handling and Storage automate the material handling and storage system reduce non-productive time reduce Work-In-Process 7. On-line Ürün Muayene incorporate quality inspection into the manufacturing process rather than traditionally placing the inspection at the completion permits corrections to the process as the product is being made reduces scrap reduces the waste of production effort on already defective parts IE321 Industrial Production Systems – Fall 2017

Automation and Production Strategies Ten Strategies for Automation and Production Systems 8. Process Control and Optimization wide range of control schemes to operate the individual processes and the associated equipment more efficiently (time and quality) 9. Plant Operations Control concerned with control at the plant level manage & coordinate aggregate operations in the plant more efficiently usually involves high level of computer networking within the factory 10. Computer Integrated Manufacturing integrate factory operations with engineering design and business functions of the firm involves extensive use of computer applications, computer data bases, and computer networking throughout the enterprise IE321 Industrial Production Systems – Fall 2017

Automation Migration Strategy Consider a situation where a company needs to introduce a new product into the marketplace in the shortest possible time often seen in competitive markets. The easiest and least expensive way to accomplish this objective is to design a manual production method, using a sequence of workstations working independently. If the capacity needs to be increased the single workstations are replicated as many times as needed to meet the demand. If the product turns out to be successful and high future demand is anticipated, then it makes sense for the company to automate production. The improvements are often carried out in phases. Many companies use an automation migration strategy, a formalized plan for evolving manufacturing systems used to produce new products as demand grows. A typical automation migration strategy has three phases: Phase 1: Manual Production Phase 2: Automated Production Phase 3: Automated Integrated Production IE321 Industrial Production Systems – Fall 2017

Automation Migration Strategy Phase 1: Manual production using single-station manned cells operating independently. A quick and low-cost tooling way to get started. manual handling manual workstation work-in-process worker starting work units completed work units Phase 1 IE321 Industrial Production Systems – Fall 2017

Automation Migration Strategy Phase 2: Automated production using single-station automated cells operating independently. As demand for the product grows, and it becemes clear that automation can be justified, then the single stations are automated to reduce labor and increase production rate. Work units are still moved between stations manually. manual handling automated workstation Aut Phase 2 IE321 Industrial Production Systems – Fall 2017

Automation Migration Strategy Phase 3: Automated integrated production using a multistation automated system with serial operations and automated transfer of work units between stations. When the company is certain that the product will be produced in mass quantities and for several years, then integration of the single-station automated cells is warrented to further reduce labor and increase production rate. Phase 3 Aut automated transfer of work units IE321 Industrial Production Systems – Fall 2017

Automation Migration Strategy Product Demand Phase 1 Phase 2 Phase 3 Time Manual Production one-station cells Automated Automated Integrated connected stations IE321 Industrial Production Systems – Fall 2017

Automation Migration Strategy Phase 1 Aut Phase 2 Product Demand Phase 1 Phase 2 Phase 3 Time Manual Production one-station cells Automated Automated Integrated connected stations Phase 3 Aut IE321 Industrial Production Systems – Fall 2017

Automation Migration Strategy The details of this strategy vary from company to company, depending on the types of products they make and the manufacturing processes they perform. The expected advantages of using such a strategy are: − allows shortest possible time to introduce new products (manual w/s) − automation is introduced gradually in planned phases as demand for the product grows, engineering changes in the products are made, and time is allowed to do a through design job on the automated manufacturing system − avoids the committment to a high level of automation from the start, since there is always a risk that demand for the product will not justify it IE321 Industrial Production Systems – Fall 2017