10. Manufacturing 3 - Digital Manufacturing and Work Measurement

Course Structure

  • The course covers the following main topics:
    • Introduction
    • Plant Layout
    • Design and Scheduling of Flow Process Systems
    • Layout for Batch Production – Singleton’s Method
    • Scheduling
    • Computer Assisted Production Planning
    • Just-in-Time Systems
    • Synchronous Production Systems and Theory of Constraints
    • Digital Manufacturing and Work Measurement

Learning Objectives

  • After this session, you should be able to:
    • Comprehend the latest developments in digital manufacturing.
    • Master the work measurement method (WMM).
    • Apply WMM for time prediction on a DM platform.

Production Systems Design

  • The production system design process includes:
    • Design Concept
    • Prototype Design
    • Prototype Build
    • Process Development
    • Preliminary Design Review & Release
    • Preproduction Build
    • Tool Design & Build
    • Design Review & Release
    • Production Units
    • Product Engineering
    • Manufacturing Engineering
    • Production

Computer Integrated Manufacturing

  • Key components of computer-integrated manufacturing include:
    • Manufacturing Database
    • Engineering Design
    • Manufacturing Engineering
    • Factory Production
    • Information Management
    • Mechanical product design
    • PCB design
    • Drafting
    • CAE (Computer-Aided Engineering)
    • CAM (Computer-Aided Manufacturing)
    • Process planning
    • Simulation
    • Robotics
    • Data collection
    • Quality assurance
    • Resources
    • Distributed control
    • Production planning & control
    • Database management
    • Communications
    • System integration

Link of Product Design and Process Engineering

  • Objectives:
    • Shorten the product development process.
    • Accelerate process design.
    • Reduce time-to-production.
    • Seamlessly transfer digital processes into production.
    • Shorten the ramp-up process.
    • Increase production efficiency.
    • Provide a bridge between CAD/CAM and execution system environments.
  • Digital Factory Drivers:
    • Cost reduction (€€).
    • Digital job planning.
    • Start time optimization.

Major Commercial Systems

  • Examples include:
    • Dassault Systems Delmia
    • Siemens UGS Tecnomatix
    • Electronic Data Systems Corporation (France, Germany, US)

Dassault Systems Products

  • Key products include:
    • CATIA (Mechanical Modeler & Sketcher)
    • DELMIA (3D PLM PPR Hub Open Gateway)
    • ENOVIA (3D PLM Enterprise Architecture)
    • CAA V5 Automation (C++/Java API, Automation API)
  • Key aspects:
    • Product, Process, Resource (PPR)
    • 3D PLM (Product Lifecycle Management)
    • RADE (Rapid Application Development Environment)

Product, Process, Resource

  • Focus:
    • Accelerates Product Synthesis and Process Optimization
    • Link of product design and process engineering
    • Collaborative infrastructure
    • Effective acquisition of information
    • Product / Process / Resource change management
    • What to Build?
    • How to Build & Maintain?

Aerospace Assembly & Integration Digital Production Solutions

  • Areas covered:
    • Resource Plant Layout
    • Process Flow Simulation
    • Conceptual Design
    • Mechanical Design
    • Product Electrical Design
    • Execution Detailed Planning
    • Process Planning
    • Conceptual Planning
    • Project Specification
    • Pre-planning Time Studies
    • Resource Planning
    • Ergo Task Sim/Validation
    • MES Integration
    • Resource Analysis
    • Layout Planning
    • Tooling Specifications
    • 3D Assy Process Validate
    • Cost Estimating
    • Assembly Planning & Sim
    • Shop floor delivery/execution
    • Throughput Analysis
    • Engineering Analysis
    • Reliability & Maintainability
    • 3D Procedures/Tech Pubs
    • Work Instruction Authoring
    • Tooling design/validation
    • Reconciliation Analysis

Digital Manufacturing

  • Encompasses:
    • Process information
    • Process times
    • Assembly stages
    • Indirect labor
    • Space requirements
    • Part bins
    • Materials
    • Throughput
    • Equipment
  • The entire planning of Product, Process, and Resources can be optimized through what-if scenarios.

Work Measurement

  • Focuses on analyzing and improving productivity.

Productivity Improvement

  • Main objective of Industrial Engineering.
  • Ways of measuring productivity:
    • Ratio between output & input
    • Standard hours/Actual hours
    • Added Value/Number of Employees
    • OEE (Overall Equipment Effectiveness)

Assessing Potential

  • Key factors:
    • Utilization
    • Performance
    • Methods

Achieving Potential - Improving Utilization

  • Strategies:
    • Planning
    • Balancing
    • Monitoring
    • Evaluating
    • Managing

Achieving Potential - Performance

  • Strategies:
    • Planning
    • Targets
    • Monitoring
    • Influencing
    • Motivating

Achieving Potential - Method

  • Steps:
    • Record
    • Analyze & Examine
    • Eliminate waste of effort
    • Eliminate waste of resource
    • Improve effectiveness
    • Improve efficiency
    • Maintain

Need for Work Measurement

  • Applications:
    • Planning (Work planning and scheduling, Resource planning)
    • Monitoring
    • Evaluating
    • Costing
    • Managing

What Is a Work Standard?

  • A work standard is a specification for performing a unit of work (operation).
  • A work standard addresses:
    • How an operation should be performed (method).
    • How long an operation should take (time).
  • Includes: Method, Time, Standard

Engineered Standards

  • Based on five assumptions:
    • Qualified Worker
    • Standard Performance
    • Prescribed Method
    • Specified Work Conditions
    • Capable Supervision

Engineered Standards - Method

  • The method in an Engineered Standard is based on the ‘Best Method’ - how a job should be done.

Engineered Standards - Time

  • The time in an Engineered Standard is established by using a valid measurement technique.

Standard Time

  • Reflects the time it should take to perform the operation using the Best Method.
  • Is determined by using a valid measurement technique.

Determining Standard Time

  • Steps:
    • Analyze manual time.
    • Measure process time.
    • Account for allowances.

Determining Standard Time - Example

  • Manual Time: 3 minutes
  • Process Time: 2 minutes
  • Basic Time: 5 minutes
  • Allowances (15%): 0.75 minutes
  • Standard Minutes: 5.75

Methods Time Measurement (MTM)

  • Based on the body motion definitions established by F.W. Taylor (1856-1915) and F.B. Gilbreth (1868 – 1924).
  • MTM is a technique used to analyze and set standard times for manual tasks by breaking them down into fundamental motions and assigning predetermined time values.
  • MTM is based on the principle that the time required to perform a certain task is dependent on specific factors like task complexity, working conditions, physical effort and worker movement. The MTM method analyses these factors and defines predetermined times for various work tasks.

Methods Time Measurement (MTM) - Data

  • Data is the result of frame-by-frame analysis of film.
  • Recognized as the most accurate and widely accepted system.

Basic Elements of MTM

  • Reach
  • Move
  • Turn
  • Apply Pressure
  • Grasp
  • Position
  • Release
  • Disengage
  • Eye Travel
  • Eye Focus
  • Leg - Foot Motion
  • Side Step
  • Turn Body
  • Walk
  • Bend
  • Stoop
  • Kneel on One Knee
  • Kneel on Both Knees
  • Sit and Stand from a Sitting Position

MTM Application Process

  • Observe the operator for job understanding
  • Establish the method
  • Break down the job into elements
  • Identify all fundamental motions in each element
  • List first letter of each basic motion
  • Assign appropriate case
  • Fill in the distances on the basic motions
  • Verify by comparison
  • Review the analysis

MTM Application Exercise

  • Example: Pickup a marker on the floor that is 3 steps away and lay it aside on the flip chart.
    • What is the elemental breakdown?

MTM Application Exercise - Breakdown

  • Walk 3 steps
  • Bend
  • Reach to the marker
  • Grasp the marker
  • Arise from bend
  • Turn body
  • Walk 3 steps
  • Move the marker to the chart
  • Release the marker
  • The corresponding TMU's (Time Measurement Units) are given for each element, totaling 201.0
  • Fundamental unit of time: 1 TMU = 0.00001 hour

Time Analysis of Aircraft Assembly

  • Integrating with digital manufacturing.

Basic MOST Process Structure Time Analysis

  • Process View: Shows Group Operations, Operations, Sub-Operations, and Activities.
  • Process Plan: Includes Time Std Hrs in library, Std Hrs / Operation, Runtime Total assy / Group, Run & Setup Total Asy. / EPR, Run & Setup Total Asy. / Line, and Run & Setup.

DPE Product Tree - Integrated Digital Manufacturing Time Analysis

  • Part attributes to be standardized include basic attributes (name and number), cost-related attributes (operation like chem-mill), and assembly-related attributes (drill type like ream).
  • Time is automatically populated through operation, assembly time calculation, intelligence algorithms, DPE process tree, Process library, and Expert system. Attributes are retrieved from the CATIA Part DPE Product Tree.

Time Analysis - Integrated Digital Manufacturing - Operation Level

  • Configure plant type, including new process views, new process plans, and operations such as locating skin panels.
  • Involves general time balancing, Simulation, analysis lines, notes, version information, value-added considerations, effectivity, attachment, and process details.

Time Analysis - Operation Level - Time Automatic Generation

  • Expert system logic for actions such as Locate (by size), Drill (by material and type), Dismantle (by size), Re-assembly (by size and wet installment), Rivet (by wet fastener and type), Trim skin panel (by type and size), and Sealing and coating (by type and length).

Time Analysis - Level of Group Operations

  • Utilize process network.
  • Add setup time & allowance.
  • Calculate process time.

Time Analysis - Level of Process Plan

  • Utilize process network
  • Add setup time for the process plan.
  • Calculate time/cost.
  • Output reports.

Review Questions

  • What is a work standard?
  • What is methods time measurement (MTM)?
  • What are the fundamental motions used in MTM?
  • How do you analyze a task to identify the fundamental motions involved?
  • What’s the fundamental unit of time in MTM?