Issues and Design Approach for Product Oriented Manufacturing Systems

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Issues and Design Approach for Product Oriented
Manufacturing Systems
IPROMS 2009 - 5th Virtual International
Conference on Innovative Production Machines and
Systems  
Universidade do Minho
Escola de Engenharia
Departamento de Produção e Sistemas

• Presented by
• Anabela Alves

On the internet , 6-17th July 2009
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Outline

• Objectives
• Product Oriented Manufacturing Systems POMS
• FOMS and POMS
• CMS and POMS
• POMS concept
• Methodologies for MSD
• Design Methodology - GCD - for POMS
• Generic
• Conceptual
• Detailed Design
• Concluding remarks

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Introduction

• Objectives
• Distinguish FOMS and CM from POMS
• Present the POMS concept
• Discuss some methodologies for MSD
• Present the Generic-Conceptual-Detailed design
  methodology for POMS
• Highlight the Generic design phase
• Fundamental decision to take selection the
  Generic Manufacturing System
• POMS or FOMS?

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Function Oriented Manufacturing System FOMS
Two radically different approaches to
Manufacturing systems organization 1.
Function/Process Oriented
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Product Oriented Manufacturing System POMS
Two radically different approaches to
Manufacturing systems organization 2. Product
Oriented
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Cellular Manufacturing System CMS
2. 1. Product Oriented
to a manufacture of similar parts or the assembly
of similar products, i.e. having similar
processing and handling requirements. But
rarely have been designed having into
consideration the need for coordinating and
synchronizing production of customer orders of
specific products, from raw materials to assembly.
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Product Oriented Manufacturing System POMS
concept
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Product Oriented Manufacturing System POMS
concept

• Requirements of POMS and design strategies
• Fast POMS design-reconfiguration
• Flexible reusable manufacturing resources
  (Equip.People)
• ...
• Movable manufacturing resources (Equip.People)
• Easier access to manufacturing resources
• Internal
• External
• Virtual reconfiguration

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Product Oriented Manufacturing System POMS
concept

• Reasons for adopting POMS
• Product focus
• Cellular organized and coordinated
• Reconfigurable and reusable manufacturing
  resources
• Varying product demands
• External requirements
• Fast delivery
• High quality of products, good customer service
• Changing product variety
• Internal
• Fast manufacturing response
• High quality production
• High manufacturing resources (EquipPeople)
  utilization
• Varying manufacturing requirements

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Design Methodologies for POMS

• Multipurpose design methodologies for
  manufacturing systems design
• Axiomatic Design Theory
• basis for developing some less general
  methodologies applied to manufacturing systems
• Methodologies with specific design purposes
• PFA, for TPS,
• naturally useful for POMS in spite of not being
  specifically oriented to that
• But
• do not comprehensively address the need for
  system integration, coordination and
  reconfiguration
• neither fully address the whole cycle of POMS
  design, from strategic to operational design

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Design Methodology for POMS

• POMS design
• Based on the Generic, Conceptual and Detailed
  (GCD) design methodology
• Generic Design
• Conceptual Design
• Detailed Design
• each phase with different design frequency
• and design agents

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Design Methodology for POMS
Overview
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Design Methodology for POMS
Generic design

• Frequency
• One time
• Period
• Years

• Agents
• Consulting and company project teams

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Design Methodology for POMS
Data bases for Generic Design
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Design Methodology for POMS

• Six criteria for select the Generic Manufacturing
  System (POMS/FOMS)
• P/Q analysis result
• Selected generic configuration
• Production strategy
• Demand structure
• Current production system
• Problems identification

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Design Methodology for POMS

• Criteria 1. P/Q analysis result (based on a
  decision table)

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Design Methodology for POMS

• Criteria 2. Selected generic configuration (based
  on the Weighted Factor Analysis)

The weight is inputed by the user of the system
according to the priorities and the winner is the
system with more points
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Design Methodology for POMS

• Criteria 3. Production strategy

The values of the first column were calculated
based on the quantification of the
characteristics of each strategy
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Design Methodology for POMS

• Criteria 4. Demand structure

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Design Methodology for POMS

• Criteria 5. Existent production system

Based on the quantification of characteristics of
each system, tries to identify the existent
production system
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Design Methodology for POMS

• Criteria 6. Problems identification

• High production times
• High WIP
• High movements times
• High set-up times
• High response times to the clients
• High number of late orders
• Reduced production flexibility
• Cost unit of product high
• Complex production planning and control

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Design Methodology for POMS

• Final decisi-on

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Design Methodology for POMS
Conceptual design

• Frequency
• Frequently
• Period
• Months

• Agents
• Consulting and company project teams
• Company project team

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Design Methodology for POMS



Detailed design

• Frequency
• Very frequently
• Period
• Days to weeks

• Agents
• Consulting and company project teams
• Production control team

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Concluding remarks

• Frequent reconfiguration for adapting POMS to
  changing product manufacturing requirements
• Manufacturing agility and leanness for gaining
  competitive advantage
• A design methodology GCD is considered for POMS
  design
• from strategic to operational design
• the strategic phase (Generic design) permits
  select the appropriate generic system
• Simple prototype of a computer aided design
  system is necessary and is being under development