1. Production Operations Management
Process Technology &
Layout
U. Akinc
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2. Various Technologies Information Technology Product Technology
Process Technology
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3. Reasons for Technology
Some of the competitive priorities
Improved Product and Service Quality
Lower Cost
Increased Responsiveness to Market
Increased Responsiveness to Customer
Safety
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4. Barriers to Implementation of Technology
Difficulty in Financial Justification
Lack of Understanding by Management
Concern for the Impact of Technology on the Human Resources
traditional ROI based capital budgeting can’t consider non-financial benefits
Resistance to change, having to learn “another way” of doing things
Fear of loss of jobs due to automation
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5. Information and Communication Technologies
Electronic Data Interchange
Bar Coding (UPC)
Electronic Pagers
Cellular Telephones
Internet/
Intranet
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6. Bar Code Technology Speeds Data Entry Increases Data Accuracy
Reduces Material Handling Labor
Easily Monitors Labor Efficiency
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7. Process Technology
Technology: Manual, Automated or Mental Processes that are Used to Transform Inputs Into Products and Services
Advanced Manufacturing Technology or Automation: Substitution of Machines for Human Physical and mental work.
Key to usage of automation: Repeatability
A task that is performed in large number of repetitions is more apt to be automated
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8. Automation and Operations Focus
Product Focus:
High Volume Standard Products imply High Degree of Repeatability
Automation is natural
Process Focus:
Low Volumes of a wide variety of product and services imply limited repeatability
Automation is more challenging
Line-Flow = flow-shop
In the form of fixed automation
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9. Fixed Automation
Automation of the processes and transfer of parts among stations. Characterized by:
High set up cost
Rigid Capabilities
Extreme efficiency
Examples:
Assembly Lines
Transfer Lines
Process industries (e.g., petro-chemicals)
Sometimes referred to as Detroit type automation
Machines that are linked with automatic materials handling
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10. An example of fixed automation: Egg processing
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11. Flexible Automation
Automatic Processes that can be easily changed from one task to another. Characterized by:
Low set up costs
A range of capabilities
Reasonably Efficient
Example:
Job Shop
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12. Group Technology
Another Attempt to obtain the efficiency of product focus without giving up the flexibility of process focus
Elements of Group Technology:
Part Families based on commonality of
Processing Steps
Part Geometry
Manufacturing Cells: Arrangement of Equipment best suited for a family
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13. Computer Integrated Manufacturing(CIM)
Integration of total manufacturing enterprise through the use of integrated systems and data communications coupled with new management philosophy that improve organizational and personnel efficiency. (SME)
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14. CIM An Umbrella term to encompass the integration of:
Product Design/Engineering
Process Planning /Development
Manufacturing Operations
Production/Inventory Control
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15. Components of CIM
1. CAD:
Computer Assisted Design: Use of Computers in interactive engineering drawing, storage and manipulation of existing designs.
2. CAM:
Computer Assisted Manufacture: Use of Computers to program, direct and control manufacturing equipment in the fabrication of parts.
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16. Components of CIM (cont’d)
3. CAPP
Computer Assisted Process Planning: Selecting operations, their sequences, tools and material handling systems using interactive computer systems
4. NC Machines
Numerically Controlled Machines:
Machines which take their instructions from a control device that can be programmed and reprogrammed in software
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17. Components of CIM (cont’d)
5.Robotics
Versatile, programmable devices capable of human like operations.
Used Mostly in:
Hazardous
Repetitive tasks
Handling Heavy Parts
Such as:
Spot welding
Inspection
Circuit board Assembly
Spray Painting
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18. A Multi-Axes Robot
Merlin1
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19. Merlin2 A Merlin robot programmed to cut carpet to specified sizes
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20. A Merlin Robot spot welding
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21. Anatomy of a Merlin robot (has three degrees of freedom or axes)
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22. Gantry Robots work like “Etch-a-sketch”
Gantry Robots work like “Etch-a-sketch”. Movement is on 3 linear axes (x,y,z) as opposed to rotational as in Merlin. This robot is installing the wind shield on a car
Gantry1
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23. Another Gantry robot: cutting cloth
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24. Components of CIM (cont’d)
6. AGV
Automatically Guided Vehicles
7. AS/RS
Automated Storage and Retrieval Systems
Please visit the link
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25. Automatically Guided vehicle examples
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26. Infrastructure of CIM Use of integrated computer software for
Production Scheduling
Inventory Control
Capacity Planning
Shop Floor Control
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27. Layout Planning
Selecting location for and transfer routes and means among work departments:
Traditional types :
Functional (Process Focus)
Line Flow (Product focus)
Fixed Position (Project)
Modern
Group Technology
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28. Functional Layout Packing Turning Gluing Cutting
Most appropriate for process focus
Packing
Turning
Gluing
Painting
Sanding
Planing
Cutting
Drilling
Resources are organized into functional departments
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29. Line Flow Layout Product flows through processes A-E
Most appropriate for Product Focus A E B C B D E A C E D A B B C
Product flows through processes A-E
in a sequence dictated by the assembly
requirements of the product. D
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30. Manufacturing Cells in Group Technology
Cell A
Refer back to slide number 12: Group Technology. Here the departments are arranged to produce families of similar parts efficiently
Cell B
Planing
Painting
Cell C
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31. A Part Family
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32. Manufacturing (GT) Cell
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33. Product Process Matrix
Product Variety and Volume
Product Process Matrix
Many
Products-
Low
Volume
Several
Products-
High
Volume
One
Product-
Very High
Volume
Low
Volume-
Unique
Identified Process Pattern
No Flow
Project
Job Shop
Jumbled Flow
Mixed with
Dominant Flows
Batch
Assembly
Line
Line Flow
Continuous
or Automated
Continuous
Process
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