Ch 1 Introduction Sections: 1.Production Systems 2.Automation in Production Systems 3.Manual Labor in Production Systems 4.Automation Principles and Strategies.

Ch 1 Introduction

Sections:

1. Production Systems

2. Automation in Production Systems

3. Manual Labor in Production Systems

4. Automation Principles and Strategies

5. Organization of the Book

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Manufacturing

Manufacturing manus (hand) + factus (make)

made by hand

Small shops Factories

Handicraft techniques Machines

Workers see the entire product Specialization

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The Realities of Modern Manufacturing

Globalization - Once underdeveloped countries (e.g., China, India, Mexico) are becoming major players in manufacturing

International outsourcing - Parts and products once made in the United States by American companies are now being made offshore (overseas) or near-shore (in Mexico and Central America)

Local outsourcing - Use of suppliers within the U.S. to provide parts and services

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More Realities of Modern Manufacturing

Contract manufacturing - Companies that specialize in manufacturing entire products, not just parts, under contract to other companies

Trend toward the service sector in the U.S. economy Quality expectations - Customers, both consumer and

corporate, demand products of the highest quality Need for operational efficiency - U.S. manufacturers must

be efficient in their operations to overcome the labor cost advantage of international competitors

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Modern Manufacturing Approaches and Technologies

Automation - automated equipment instead of labor (reduces labor cost, decreases production cycle times, increases product quality and consistency)

Material handling technologies - manufacturing usually involves a sequence of activities; material handling provides transportation, storage and tracking of materials through the plant

Manufacturing systems - integration and coordination of multiple automated or manual workstations through material handling technologies

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Modern Manufacturing Approaches and Technologies

Flexible manufacturing - to compete in the low-volume/high-mix product categories

Quality programs - to achieve the high quality expected by today's customers

Computer Integrated Manufacturing (CIM) - to integrate design, production, and logistics

Lean production - more work with fewer resources

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Production System Defined

“A collection of people, equipment, and procedures A collection of people, equipment, and procedures organized to accomplish the manufacturing operations of organized to accomplish the manufacturing operations of a companya company”

Two categories: Facilities – the factory and equipment in the facility and

the way the facility is organized (plant layout) Manufacturing support systems – the set of procedures

used by a company to manage production and to solve technical and logistics problems in ordering materials, moving work through the factory, and ensuring that products meet quality standards

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The Production System

Fig. 1.1

Blue collar

White collar

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Production System Facilities

Facilities include the factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations

Plant layout – the way the equipment is physically arranged in the factory

Manufacturing systems – logical groupings of equipment and workers in the factory Production line Stand-alone workstation and worker

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Manufacturing Systems

Three categories in terms of the human participation in the processes performed by the manufacturing system:

1. Manual work systems - a worker performing one or more tasks without the aid of powered tools, but sometimes using hand tools

2. Worker-machine systems - a worker operating powered equipment

3. Automated systems - a process performed by a machine without direct participation of a human

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Manual Work System (Fig. 1.2.a)

A manual work system consists of one or more workers performing one or more tasks without the aid of powered tools.

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Worker-Machine System (Fig. 1.2.b)

A human worker operates a powered machine, such as a machine tool or other production machine.

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Automated System (Fig. 1.2.c)

An automated system is one in which a process is performed by a machine without the direct participation of a human worker.

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Automated System

A semi-automated machine performs a portion of the work cycle under some form of program control, and a human worker tends to the machine for the remainder of the cycle, by unloading and loading it, or performing some other task each cycle.

A fully automated machine has the capacity to operate for extended periods of time with no human attention.

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Manufacturing Support Systems

““People and procedures by which a company manages its productionPeople and procedures by which a company manages its production

Operations”Operations” Design the process and equipmentDesign the process and equipment Plan and control the production ordersPlan and control the production orders Satisfy product quality requirementsSatisfy product quality requirements

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Manufacturing Support Systems

Involves a cycle of information-processing activities that consists of four functions:• Business functions – principal means of communicating with

customer

The production order will be in one of the following forms:

1. an order to manufacture an item to the customer’s specifications

2. a customer order to buy manufacturer’s product

3. an internal company order based on a forecast of future demand

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Manufacturing Support Systems

• Product design - research and development, design engineering, prototype shop

• Manufacturing planning – the information and documentation that constitute the product design flows into the manufacturing planning function• Process planning: consists of determining the sequence of individual

processing and assembly operations needed to produce the part • Master Production Schedule (MPS) is a listing of the products to be

made, the dates on which they are to be delivered, and the quantities of each

• Materials Requirement Planning (MRP): planning of individual components and subassemblies that make up each product

• Capacity planning is concerned with manpower and machine resources of the firm

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Manufacturing Support Systems

• Manufacturing control – concerned with managing and controlling the physical operations in the factory to implement the manufacturing plans• Shop floor control deals with the problem of controlling the

progress of the product as it is being processed, assembled, moved, and inspected in the factory

• Inventory control attempts to strike a proper balance between the risk of too little inventory (with possible stock-out of materials) and the carrying cost of too much inventory, i.e. what to order and when to order

• Quality control ensures that the quality of product and its components meet the standards specified by the product designer

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Information Processing Cycle in Manufacturing Support Systems

Fig. 1.3

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Automation in Production Systems

Two categories of automation in the production system:

1. Automation of manufacturing systems in the factory

2. Computerization of the manufacturing support systems

The two categories overlap because manufacturing support systems are connected to the factory manufacturing systems Computer-Integrated Manufacturing (CIM)

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Computer Integrated Manufacturing

Fig. 1.4 Opportunities for automation and computerization in a production system

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Automated Manufacturing Systems

processing assembly inspection material handling

They are called automated because they perform their operations with a reduced level of human participation compared with the corresponding process (sometimes virtually no human participation)

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Automated Manufacturing Systems

Examples: Automated machine tools Transfer lines Automated assembly systems Industrial robots that perform processing or

assembly operations Automated material handling and storage systems to

integrate manufacturing operations Automatic inspection systems for quality control

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Automated Manufacturing Systems

Three basic types:

1. Fixed automation

2. Programmable automation

3. Flexible automation

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Fixed Automation

““A manufacturing system in which the sequence of A manufacturing system in which the sequence of processing (or assembly) operations is fixed by the processing (or assembly) operations is fixed by the equipment configurationequipment configuration””

Typical features: Suited to high production quantities High initial investment for custom-engineered equipment High production rates Relatively inflexible in accommodating product variety

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Fixed Automation

The economic justification for fixed automation is found in products that are produced in very large quantities

Transfer lines Automated assembly lines

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Programmable Automation

““A manufacturing system designed with the capability A manufacturing system designed with the capability to change the sequence of operations to to change the sequence of operations to accommodate different product configurationsaccommodate different product configurations””

Typical features: High investment in general purpose equipment Lower production rates than fixed automation Flexibility to deal with variations and changes in

product configuration Most suitable for batch production Physical setup and part program must be changed

between jobs (batches)

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Programmable Automation

The operation sequence is controlled by a program, which is a set of instructions coded so that they can be read and interpreted by the system.

New programs can be prepared and entered into equipment to produce new products.

Numerically controlled (NC) machine tools Industrial robots Programmable logic controllers

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Flexible Automation

““An extension of programmable automation in which the An extension of programmable automation in which the system is capable of changing over from one job to the system is capable of changing over from one job to the next with no lost time between jobsnext with no lost time between jobs””

Typical features: High investment for custom-engineered system Continuous production of variable mixes of products Medium production rates Flexibility to deal with soft product variety

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Product Variety and Production Quantity for Three Automation Types

Fig. 1.5

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Computerized Manufacturing Support Systems

Objectives of automating the manufacturing support systems: To reduce the amount of manual and clerical effort in product

design, manufacturing planning and control, and the business functions

Integrates computer-aided design (CAD) and computer-aided manufacturing (CAM) in CAD/CAM

CIM includes CAD/CAM and the business functions of the firm

The term CIM denoted the pervasive use of computer systems to design the products, plan the production, control the operations, and perform the various information-processing functions needed in a manufacturing firm.

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Reasons for Automating

1. To increase labor productivity

2. To reduce labor cost

3. To mitigate the effects of labor shortages

4. To reduce or remove routine manual and clerical tasks

5. To improve worker safety

6. To improve product quality

7. To reduce manufacturing lead time

8. To accomplish what cannot be done manually

9. To avoid the high cost of not automating

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Manual Labor in Production Systems

Is there a place for manual labor in the modern production system? Answer: YES

Two aspects:

1. Manual labor in factory operations

2. Labor in manufacturing support systems

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Manual Labor in Factory Operations

The long term trend is toward greater use of automated systems to substitute for manual labor

When is manual labor justified? Some countries have very low labor rates and

automation cannot be justified Task is too technologically difficult to automate Short product life cycle Customized product requires human flexibility To cope with ups and downs in demand To reduce risk of product failure

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Labor in Manufacturing Support Systems

Product designers who bring creativity to the design task Manufacturing engineers who

Design the production equipment and tooling, and Plan the production methods and routings

Equipment maintenance Programming and computer operation Engineering project work Plant management

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Automation Principles and Strategies

The preceding discussion leads us to conclude that automation is not always the right answer for a given production situation. A certain caution and respect must be observed in applying automation technologies.

1. The USA Principle

2. Ten Strategies for Automation and Process Improvement

3. Automation Migration Strategy

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U.S.A Principle

1. Understand the existing process Input/output analysis Value chain analysis Charting techniques and mathematical modeling

2. Simplify the process Reduce unnecessary steps and moves

3. Automate the process Ten strategies for automation and production

systems Automation migration strategy

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Ten Strategies for Automation and Process Improvement

If automation seems a feasible solution to improving productivity, quality or other measure of performance, then the following ten strategies provide a road map to search for these improvements.

1. Specialization of operations: The use of special-purpose equipment designed to perform one operation with the greatest possible efficiency.

2. Combined operations: Involves reducing the number of distinct production machines or workstations through which the part must be routed. Saves setup, material handling effort, waiting time, lead time.

3. Simultaneous operations: Reduces total processing time.©2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems,

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Ten Strategies for Automation and Process Improvement

4. Integration of operations: Linking several workstations together into a single integrated mechanism, using automated work handling devices to transfer parts between stations.

5. Increased flexibility: Attempts to achieve maximum utilization of equipment for job-shop and medium-volume situations by using the same equipment for a variety of parts or products (reduce setup and programming time).

6. Improved material handling and storage: Reduces WIP and shortens manufacturing lead time.

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Ten Strategies for Automation and Process Improvement

7. On-line inspection: Permits corrections to the process as the product is being made (reduces scrap, improves quality)

8. Process control and optimization: Control at process/machine level

9. Plant operations control: Control at plant level

10. Computer-integrated manufacturing: Integration of factory operations with design and the business functions.

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Automation Migration Strategy For Introduction of New Products

A formalized plan for evolving the manufacturing systems used to produce new products as demand grows.

1. Phase 1 – Manual production Single-station manned cells working independently Advantages: quick to set up, low-cost tooling

2. Phase 2 – Automated production Single-station automated cells operating independently As demand grows and automation can be justified

3. Phase 3 – Automated integrated production Multi-station system with serial operations and

automated transfer of work units between stations

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Automation Migration Strategy

Fig. 1.6

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Organization of the Book

1. Overview of Manufacturing

2. Automation and Control Technologies

3. Material Handling and Identification Technologies

4. Manufacturing Systems

5. Quality Control in Manufacturing Systems

6. Manufacturing Support Systems

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Organization of the Book

Fig.1.7

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