Chapter 1 LN
Chapter Overview
Introduction to Manufacturing
Instructor: Assoc. Prof. Dr Abdullah Hj Yassin
Course Code: KNP4073 Advanced Manufacturing System
Chapter 1: Introduction to Manufacturing
Contents
Production Systems
Automation in Production Systems
Manual Labor in Production Systems
Automation Principles and Strategies
The Realities of Modern Manufacturing
Key Factors
Globalization
Previously underdeveloped countries like China, India, and Mexico are now key manufacturers.
International Outsourcing
Shift of production from local to overseas providers.
Local Outsourcing
Utilizing domestic suppliers for parts and services.
Additional Aspects
Contract Manufacturing
Specialized companies produce complete products under contracts.
Quality Expectations
High-quality products are demanded by consumers and corporations.
Operational Efficiency
Manufacturer efficiency is crucial to compete with international labor cost advantages.
Modern Manufacturing Approaches and Technologies
Technologies and Strategies
Automation
Replacing labor with automated equipment.
Material Handling Technologies
Essential for the sequential nature of manufacturing operations.
Manufacturing Systems
Integration and coordination of automated/manual workstations.
Flexible Manufacturing
Adapting to low-volume/high-mix production.
Quality Programs
Ensuring high quality to meet customer expectations.
CIM (Computer Integrated Manufacturing)
Integrates design, production, and logistics.
Lean Production
Achieving more output with fewer resources.
Production System Defined
Overview
Definition
A collection of people, equipment, and procedures for manufacturing operations.
Categories
Facilities
Comprises factory, equipment organization, and plant layout.
Manufacturing Support Systems
Procedures for managing production and solving logistical issues.
Production System Facilities
Components
Facilities Include
Factory, production machines, tooling, inspection equipment, and computer systems.
Plant Layout
Arrangement of equipment within the factory.
Manufacturing Systems
Logical groupings of equipment and workers.
Examples: Production line, standalone workstations.
Human Participation in Manufacturing Systems
Categories of Work Systems
Manual Work Systems
Tasks performed without powered tools, sometimes assisted by hand tools.
Worker-Machine Systems
Workers operating powered equipment.
Automated Systems
Processes executed by machines without human intervention.
Manufacturing Support Systems
Information-Processing Activities
Business Functions
Sales, marketing, order entry, cost accounting, customer billing.
Product Design
Research, development, design engineering, prototype creation.
Manufacturing Planning
Process and production planning, Material Requirements Planning (MRP), capacity planning.
Manufacturing Control
Shop floor management, inventory control, quality assurance.
Automation in Production Systems
Categories
Automation of Manufacturing Systems
Computerization of Support Systems
Interconnected systems between manufacturing support and production systems, known as CIM.
Automated Manufacturing Systems
Examples
Automated machine tools
Transfer lines
Automated assembly systems
Industrial robots
Automated material handling and inspection systems.
Types of Automation
Fixed Automation
High-production systems with fixed operation sequences.
Programmable Automation
Ability to change operation sequences for different goods.
Flexible Automation
System can switch between different jobs with little downtime.
Product Variety and Production Quantity for Automation Types
Fixed automation: High quantity (1,000,000)
Programmable: Mid-range (10,000)
Flexible: Low (1)
Computerized Manufacturing Support Systems
Objectives
Reduce manual effort in design, planning, and business functions.
Integrate CAD and CAM into a comprehensive CIM system.
Reasons for Automation
Increase labor productivity
Lower labor costs
Address labor shortages
Eliminate repetitive clerical tasks
Enhance worker safety
Improve product quality
Shorten manufacturing lead times
Enable tasks beyond human capabilities
Mitigate high costs of manual processes.
Manual Labor in Production Systems
Justifications for Manual Labor
Economic conditions in certain countries.
Technological limitations in automation.
Customized products requiring human adaptability.
Short product life cycles and demand variability.
Types of Roles for Manual Labor
Creative product designers.
Manufacturing engineers for equipment and production planning.
Maintenance, programming, and management roles.
Automation Principles and Strategies
Important Principles
Understanding existing processes (input/output analysis, value chains).
Simplifying processes by removing unnecessary steps.
Automating processes based on assessed needs.
Ten Strategies for Automation
Specialization of operations
Combined operations
Simultaneous operations
Integration of operations
Increased flexibility
Enhanced material handling
On-line inspection
Process optimization
Plant operations control
Computer-integrated manufacturing.
Automation Migration Strategy
Phases for New Product Introduction
Phase 1: Manual production with independent workstations.
Phase 2: Automated production as demand justifies.
Phase 3: Fully integrated automated production for mass output.
Advantages of Strategy
Quick product introduction.
Gradual automation minimizes risk of over-investment.
Review Questions
What differentiates manufacturing systems from production systems?
Manufacturing systems are groupings of equipment and operators; production systems encompass whole sets including managing support systems.
What types of work still require human input in factory settings?
Maintenance, programming, engineering, and management.
What is an automation migration strategy?
A structured approach to evolving manufacturing systems as demand for new products changes.