Manufacturing Systems Materials + Machine Time + Labor = Manufactured Goods

STRATGIEG AND DESIGNE OF MANUFACTURING SYSTEM

Manufacturing Systems Custom Manufacturing Continuous Manufacturing Intermittent Manufacturing Flexible Manufacturing Just-In-Time Manufacturing

Custom Manufacturing Oldest production system Used to produce a smaller number of products to a customer’s order Highly skilled workers machines to produce individual parts Examples – spacecraft, stamping dies, special purpose machines

Continuous Manufacturing Special purpose machines are used to produce large quantities of products Products have limited variations Uniform parts flow from station to station Semiskilled workers operate the stations Examples – automobiles, household appliances, furniture, paper, and lumber

Intermittent Manufacturing Used when continuous manufacturing is not practical Producing products in lots All of the parts are processed through the station together Often referred to as job-lot manufacturing

Flexible Manufacturing Use of special tools and machines Computer-controlled machines allow production run to be small Reduced set-up time Increased quality control with the use of the computer Lots as small as one product can be produced at the cost of continuous manufacturing

Just-In-Time Manufacturing Computer-based monitoring system Developed in Japan JIT stresses effective use of resources Focus is placed on eliminating tasks, such as transportation, inspection, and storage which are wasteful Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders

1. Which answer choice defines custom manufacturing? Stop for Questions Special purpose machines are used to produces a large number of goods as parts move from one station to the next Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders Producing products in lots Oldest form of manufacturing that is used to produce a smaller number of goods

2. Which answer choice defines continuous manufacturing? Stop for Questions Special purpose machines are used to produces a large number of goods as parts move from one station to the next Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders Producing products in lots Oldest form of manufacturing that is used to produce a smaller number of goods

3. Which answer choice defines intermittent manufacturing? Stop for Questions Special purpose machines are used to produces a large number of goods as parts move from one station to the next Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders Producing products in lots Oldest form of manufacturing that is used to produce a smaller number of goods

4. Which answer choice defines flexible manufacturing? Stop for Questions Special purpose machines are used to produces a large number of goods as parts move from one station to the next Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders Producing products in lots Oldest form of manufacturing that is used to produce a smaller number of goods

5. Which answer choice defines just-in-time manufacturing? Stop for Questions Special purpose machines are used to produces a large number of goods as parts move from one station to the next Computer controlled machines are used to produce lots as small as one product but at the cost of continuous manufacturing Raw materials arrive JIT for production, parts are produced JIT to be assembled, and products are produced JIT to meet the customer delivery orders Producing products in lots Oldest form of manufacturing that is used to produce a smaller number of goods

6. Is an automobile custom or continuous manufacturing? Stop for Questions Continuous Manufacturing Custom Manufacturing

7. Is a space shuttle custom or continuous manufacturing? Stop for Questions Continuous Manufacturing Custom Manufacturing

8. Is a household appliance custom or continuous manufacturing? Stop for Questions Continuous Manufacturing Custom Manufacturing

HOW TO CHOOSE BETWEEN THEM  •    How much will it take in both effort and energy for you to be able to obtain, implement and maintain consistency with the manufacturing system you will go with? Which of the systems available will best benefit the type of manufacturing you are planning?  •    How much will it take in both effort and energy for you to be able to obtain, implement and maintain consistency with the manufacturing system you will go with?  CONTD……

COMPONENTS OF MANUFACTURING SYSTEM

CONTD…..  •   How easy or difficult will it be for the employees, managers and owners to implement and maintain the manufacturing system?   •  How much will the manufacturing system cost, and what can you afford to spend?    •Will the cost efficiency from the manufacturing system resolve into enough of a saving of cost, to benefit the cost of the program?

Flexible Manufacturing System(FMS) A Closer Look

Application of FMS Metal-cutting machining Metal forming Assembly Joining-welding (arc , spot), glueing Surface treatment Inspection Testing

FMS different approaches The capability of producing different parts without major retooling A measure of how fast the company converts its process/es from making an old line of products to produce a new product The ability to change a production schedule, to modify a part, or to handle multiple parts

Advantages of using FMS To reduce set up and queue times Improve efficiency Reduce time for product completion Utilize human workers better Improve product routing Produce a variety of Items under one roof Improve product quality Serve a variety of vendors simultaneously Produce more product more quickly

FMS Example Body Shop Paint Shop Final Assembly Through the use of reprogrammable tooling in the body shop, standardized equipment in the paint shop and common build sequence in final assembly, Ford can build multiple models on one or more platforms in one plant. In the body shop, where the sheet metal comes together to form the vehicle’s body, flexibility means more than 80 percent of the tooling is not specific to one model. It can be reprogrammed to weld a car or a truck or a crossover of similar size. Body Shop In the paint shop, flexibility means robotic applicators are programmed to cover various body styles – as they move through the paint booth – with equal precision. This results in minimizing waste and environmental impact while maximizing quality. Paint Shop In the final assembly area, flexibility means the build sequence is the same among multiple models on one or more platforms allowing for efficient utilization of people and equipment. Final Assembly

Illustration example of a FMS

Disadvantage of using FMS Limited ability to adapt to changes in product or product mix (ex:machines are of limited capacity and the tooling necessary for products, even of the same family, is not always feasible in a given FMS) Substantial pre-planning activity Expensive, costing millions of dollars Technological problems of exact component positioning and precise timing necessary to process a component Sophisticated manufacturing systems

Development of FMS Several actions must be decided on before you can have a have a FMS.  These actions include. Selecting operations needed to make the product. Putting the operations in a logical order. Selecting equipment to make the product. Arranging the equipment for efficient use. Designing special devices to help build the product. Developing ways to control product quality.