Engineering Manufacturing Facilities 22 Engineering Manufacturing Facilities

Objectives List the major engineering tasks in organizing a manufacturing operation. Describe how the manufacturing engineer performs these tasks. Demonstrate the use of forms such as the operation process chart and the flow process chart.

Engineering Manufacturing Facilities Engineered facilities Permit efficient production Manufacturing engineers Design and develop facilities for approved products Allow production at a competitive price

Selecting and Sequencing Operations Plant engineering Deciding needed processes (selecting) Putting them in order (sequencing) Manufacturing engineers organize with Forms Methods

Operations Sheet Engineers must analyze the product drawings to determine needed operations Operations sheet includes: Operation name Machines needed Tooling needed

Additional Forms A flow process chart allows engineers to: Study the sequence of operations Identify the best ways to make a part Uses industry standard symbols

Flow Process Chart Describes the tasks Provides code numbers for each task Identifies machines Lists tooling needed for the task Does not let you view the whole system

Flow Process Chart (Cont.)

Operations Process Chart Shows the whole system for the product How each part is made How they are assembled Where operations and inspections fit in Used in scheduling production Allows engineers to analyze the overall manufacturing process

Operations Process Chart (Cont.) Tasks not included: Transportation Delay Storage

Designing Tooling Tooling is designed to increase the operation’s: Speed Accuracy Safety

Preparing Plant Layout Resource flow Manufacturing engineers plan Machine placement Material movement Utility location Aisles

Plant Layout Process layout Custom manufacturing Intermittent manufacturing

Plant Layout (Cont.) Product layout Continuous manufacturing

Communicating Layouts Manufacturing engineers must document and communicate their designs Plant layout drawings Models

Material Handling Fixed path devices move a product from one fixed point to another Assembly lines Conveyors Pipes Elevators Chutes

Material Handling (Cont.) Variable path devices move product in a number of different directions Forklifts Overhead cranes Tractors Hand trucks Require an operator

Improving Manufacturing Systems Production lines redesigned and improved More efficient machines and tooling Better material-handling devices Improved material flow Operations refined

Review Question An efficiently designed manufacturing facility will produce its products at a(n) _____. competitive price

Review Question Who is responsible for the design and development of manufacturing facilities? Manufacturing engineers

Review Question What are the major tasks in organizing a manufacturing operation? Selecting and sequencing operations, designing tooling, preparing plant layout, designing material handling systems, improving manufacturing systems.

Review Question The _____ includes operation name, machine used, and tooling needed to produce a product. operation sheet

Review Question The _____ describes each task, codes each task, identifies machines to be used, and lists tooling for the task. flow process chart

Review Question The _____ shows how each part is made and how they are assembled into a final product. operation process chart

Review Question True or False? Material handling is a term used to describe devices such as jigs, fixtures, patterns, and templates used to make workers faster, more accurate, safer. False

Review Question _____ layouts are used to design a factory around the production of one specific product. A. Process B. Product C. Tooling D. Material

Review Question True or False? Process layouts group machines by the processes they perform. True

Review Question True or False? Variable path devices move a product from one fixed point to another. False

Glossary Competitive price Flow process chart Manufacturing engineer a price at which a product can be produced cheaply enough to sell at a price similar to like products on the market. Flow process chart a graphic means of showing all the steps and processes a single part goes through as it is manufactured. Manufacturing engineer a professional person who organizes manufacturing operations.

Glossary Material handling Operations Operation sheet Process layout the methods used to move material around a manufacturing plant. Operations the processes that shape and assemble a product. Operation sheet a form used to record the sequence of operations needed to produce a product. Process layout a type of plant layout where machines are grouped by the process they perform.

Glossary Product layout Resource flow Tooling A manufacturing arrangement in which equipment is arranged in the sequence of operations needed to produce the product. Resource flow the flow of materials and people inside a plant. Tooling devices such as jigs, fixtures, patterns, and templates that help workers make products better and faster. Tooling is designed for three purposes: to increase speed, accuracy, and safety.