Ch. 8: Manufacturing Systems

Manufacturing

• Value-adding function

• Efficiency of activities will make a major contribution to firm’s long and short term goals/profitability

• Quality: Delivering on promises

Factors Influencing Facility Layout and Material Handling

1. Product mix and design 

2. Materials and processing tech.

3. Handling, storage and control tech.

4. Production volumes, schedules and routings 

5. Management philosophies 

Automatic Factory

• Paperless 

• Personnel make every effort to make sure unusual situations don’t happen

Automated Factory

• Automation and mechanization are dominant

• People perform indirect tasks instead of direct ones 

• Personnel resolve unusual situations 

Transfer Lines

• Material flow from one workstation to the next in a sequent 

• Advantages:

  • High volume production, highly automated

  • High speed, lack of buffering storage

• Disadvantages

  • High equipment cost

  • Inflexibility about number of prod. Produced

  • Inflexibility of layout

  • One machine failure cause dominoes

Dial Indexing Machine

• Workstations and the input/output stations are arranged in a circular pattern

• Clockwise or counterclockwise

• Advantages:

  • Fixed automation

  • Processing is synchronous

  • Parts move without manual intervention 

Plant Wide Control Systems 

• Tie all automated hardware system subsystems 

• Include: 

  • Intergrade material handling information flow with shop floor control information

  • Assign and schedule material handling resources

  • Provide real-time control over material move, store and retrieve actions

Flexible Manufacturing System

• FMS

• Ability to produce many different parts 

• Batch-type metal-cutting production, a component/piece spends only 5% of
  it’s time on machine tools

• Gaining control of 95% of the time parts are not machined , by automatically
  linking the machines using material handling machines and computerizing the entire operation

Design Requirments for FMS

• Independant movement between stations 

• Temporary storage 

• Convenient access for loading and unloading 

• Future expansions considerations 

• Industrial codes 

• Easy access to machine tools 

• Operation in shop environment 

What makes FMS Flexible?

• Must have the following?:

  • Process different changes in production schedule

  • Accept changes in production schedule

  • Respond easily to equipment malfunction and or breakdown

  • Accomdate the intro to new part designs

Single Stage Multimachine Systems (SSMS)

• Alt in automation in machining systems

• Resources involved

  • Manufacturing configuration and machines

  • Parts

  • Tools

  • Part transfer

  • Tool carriers

In-Process Handling 

Includes movement of material, tooling and supplies to and from production units 

In-Process Storage

Includes the storage of material, tooling and supplies to support production

Just In Time Manufacturing

• JIT

• Developed 50+ years ago by Ohno Taiichi by Toyota

• Reducing man hours to improve efficency

Waste Divisions 

• Overproduction 

• Time on band (waiting)

• Transporting 

• Processing 

• Unnecessary stock on hand 

• Unncessary motion 

• Producing defective goods 

Five Elements of JIT

1. Visability

2. Simiplicity

3. Flexibility

4. Standardization

5. Organization

U-Shaped Flow Lines

• Parts from similar characteristics are grouped together for processing in a common area

• Used in a manufacturing cell

• Better communication

• 25% manned by one operator

• Increased productivity and less defects