Manufacturing Systems Facilities and Technology Volume and Variety Facility Layout Technology Compiled by: Alex J. Ruiz-Torres, Ph.D. From information developed by many.

Mfg Facilities and Technology The type of product and the customer requirements dictates the technologies used and the type of facility. Key characteristics Variety: will it produce a few/ standardized products or many different types (even customized products). Volume: relative measure of how much will the system produce (5 computers per day, 2,000 computers per day)

Mfg Technology and Facilities Volume and variety are directly associated with the level of automation and standardization of the production process. This drives the efficiency and cost. An artisan making wooden saints - makes 1 every week One hundred artisans in a factory following the same process and with the same equipment in a), would make 100 units per week. One hundred artisans using a specialized process (for example, the best artisans at making the head, make the head, the best ones at carving the arms ….), plus they use some automated machines, could make 200 units per week.

Volume and Variety The Product-Process Matrix Volume Variety Few product types made in high volume; specialized equipment; significant automation; highly efficient; low cost per unit. Continuous Process/ Assembly Line High Volume Batch/Flow Shop The middle…. Low Job Shop Many product types each produced in very small amounts (sometimes only one); general purpose equipment; little or no automation; low efficiency; high cost per unit. Low High Variety

Volume and Variety Example: Cakes. Assembly line mass produced in specialized lines inflexible huge volumes typically lowest cost per slice of cake. Image Sources: Youtube.com, everychina.com https://raosbakery.com/cakes/ https://intl.target.com/p/pepperidge-farm-3-layer-cake-chocolate-19-6-oz/-/A-13583125

Volume and Variety Batch production smaller quantities more versions/ types of products, even seasonals semi dedicated production lines higher cost than previous case.

Volume and Variety Job shop make to order (MTO) no specialized equipment each cake is a new project typically highest cost per slice of cake.

Facility Layout Facility layout relates to the placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility. http://www.capplustech.com/softgel/plant_layout.htm https://www.indiamart.com/proddetail/factory-layout-planning-service-10679221248.html

Facility Layout Two basic forms Product based: the facility is organized around the flow of one or a few products. Facilities with assembly lines. Process based: the facility is organized around equipment and groups dedicated to processes. Different products may have different flows across the layout. product flow line 1 stores shipping line 2 line 3 5 stores cut/ sand 4 1 3 painting testing shipping 2 welding electronic assembly http://www.alamy.com/stock-photo-china-workers-at-the-assembly-line-of-a-toy-factory-in-guangdong-province-37879913.html

Facility Layout The layout has an effect in many measures of performance: Movement time - longer distances = more time moving. Number of touches which is related to labor costs. Inventory locations often dictate inventory quantities and therefore costs. Poor layouts result in materials or people getting lost / temporarily disappearing.

Manufacturing Technology Equipment and information technologies. Equipment tech to make, assemble, test, and pack the products. Information tech to support decision making. Technology replaces operators. Technology allows for faster and higher quality production.

Manufacturing Technology Computer controlled production equipment is prevalent in some industries such as automobile and electronic production. Drawbacks: Sometimes it limits flexibility (equipment is difficult to modify), Requires significant investments and know how. http://www.nytimes.com/2012/08/19/business/new-wave-of-adept-robots-is-changing-global-industry.html

Manufacturing Technology 3D manufacturing: process to make a product by adding material using computer controlled systems. This technology replaces traditional processes as cutting, milling, molding,… http://cerasis.com/2014/12/10/3d-printing-in-manufacturing/ http://edition.cnn.com/TECH/specials/make-create-innovate/3d-printing/ http://www.3ders.org/articles/20160615-airbus-apworks-altair-announce-additive-manufacturing-partnership-following-3d-printed-motorcycle-project.html